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Full text of "Zebra S-Series User Manual"

S-Series 
User's Guide 



For the Zebra 105Se™ 
and 1605™ Printers 



Customer Order # 11991L 
Manufacturer Part # 11 991 LB Rev. 2 




Proprietary Statement 

This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the 
information and use of parties operating and maintaining the equipment described herein. Such proprietary 
information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed 
written permission of Zebra Technologies Corporation. 

Product Improvements 

Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and signs are 
subject to change without notice. 

FCC Compliance Statement 

Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to 
Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference 
when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio 
frequency energy and, if not installed and used in accordance with the instructions manual, may cause harmful 
interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful 
interference in which case the user will be required to correct the interference at his own expense. 

In order to ensure compliance, this printer must be used with a Shielded Power Cord and Shielded Communication 
Cables. 

"The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corporation 
could void the user's authority to operate the equipment." 

Canadian DOC Compliance Statement 

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in 
the radio interference regulations of the Canadian Department of Communications. 

Liability Disclaimer 

Zebra Technologies Corporation takes steps to assure that its published Engineering Specifications and Manuals are 
correct; however, errors do occur. Zebra Technologies Corporation reserves the right to correct any such errors and 
disclaims liability resulting therefrom. 

No Liability for Consequential Damage 

In no event shall Zebra Technologies Corporation or anyone else involved in the creation, production, or delivery of 
the accompanying product (including hardware and software) be liable for any damages whatsoever (including, 
without limitation, damages for loss of business profits, business interruption, loss of business information, or other 
pecuniary loss) arising out of the use of or the results of use or inability to use such product, even if Zebra 
Technologies Corporation has been advised of the possibility of such damages. Because some states so not allow the 
exclusion or limitation of liability for consequential or incidental damages, the above limitation may not apply to you. 

Copyrights 

This copyrighted manual and the label printer described herein are owned by Zebra Technologies Corporation. All 
rights are reserved. Unauthorized reproduction of this manual or the software in the label printer may result in 
imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil 
liability. 

© 2001 Zebra Technologies Corporation. All rights reserved. 

All products and brand names are trademarks of their respective companies. All rights reserved. 



Zebra S-Series User's Guide ii 



Table of Contents 



Introduction 1 

Scope 1 

Model Designation 1 

System Overview 2 

Communication Capabilities 2 

Thermal Transfer Printer Internal Functions 2 

Print Mechanism Capabilities 2 

Media Transport Mechanism Capabilities 3 

Additional System Requirements 3 

Media and Ribbon Requirements 4 

Warnings and Precautions 4 

Installation 4 

230 VAC Operation 4 

Use of Shielded Cable 5 

Ribbons and Printhead Wear 5 

Repacking 5 

Installation 7 

Unpacking 7 

Inspection 7 

Reporting Damage 7 

Storage and Reshipping 8 

Power Connection 8 

AC Voltage Selection Procedure 8 

AC Power Fuse Replacement 9 

115 VAC Operation 10 

230 VAC Operation 10 

Site Requirements 10 

Ribbon Loading (1 05 Se) 11 

Ribbon Loading (1 60S) 14 



Zebra S-Series User's Guide iii 



Media Loading 15 

Roll Media 15 

Tear-Off Mode 17 

Rewind Mode 17 

Peel-Off Mode 17 

Cutter Mode 18 

Fanfold Media 18 

Removing Used Ribbon (105Se) 19 

Removing Used Ribbon (160S) 20 

Initial Printer Power Up 21 

Operation 23 

Operating Your Zebra. S-Series Printer 23 

Printer Operating Modes 23 

Media Sensing Modes 23 

Media Transport Modes 24 

Front Panel Keys 26 

PAUSE Key 26 

FEED Key 26 

CANCEL Key 26 

MODE Key 27 

Front Panel Lights 27 

Power-On Self Test 28 

Printer Self Tests 28 

Introduction 28 

CANCEL Key Self Test 30 

PAUSE Key Self Test 31 

FEED Key Self Test 32 

FEED Key and PAUSE Key Self Test 33 

MODE Key Self Test 33 

PAUSE Key and CANCEL Key Self Test 33 

FEED Key and CANCEL Key Self Test 34 

Extended Printer Diagnostics 34 

Sample ZPL II® Label Formats 35 

Format 1: Simple Text and a Barcode 36 

Format 2: Saving a Label Format as a Graphic Image 36 

Format 3: Using a Serialized Data Field 37 



Zebra S-Series User's Guide iv 



Configuration and Calibration 39 

Option Switches 39 

Bankl 40 

Bank 2 41 

Configuration Mode 42 

Calibration 43 

Adjusting the Print Darkness 44 

Adjusting the Media Rest Position 44 

Adjusting the Position of the Top of the Label 44 

Interconnections 45 

System Components 45 

System Considerations 45 

Communications Code 45 

Interfaces 46 

Data Specifications 46 

RS-232 Serial Data Port 46 

RS-232 Pinouts 46 

Hardware Control Signal Descriptions 47 

RS-232 Cabling Requirements 47 

Interconnect to DTE Devices 48 

Interconnect to DCE Devices 48 

Parallel Cabling Requirements 49 

Parallel Interface 49 

Signal Descriptions 50 

Preventive Maintenance 51 

Overview 51 

Cleaning 51 

Exterior Surfaces 51 

Interior 51 

Printhead and Platen Roller 52 

Media, Ribbon, and Label Available Sensors 57 

Cutter Module 57 

Lubrication 58 



Zebra S-Series User's Guide 



Adjustments 59 

Toggle Positioning 59 

Printhead Pressure Adjustment 59 

Black Mark Media Sensor Position Adjustment 60 

Transmissive Media Sensor Position Adjustment 60 

Upper Transmissive Media Sensor Position Adjustment 61 

Lower Transmissive Media Sensor Position Adjustment 62 

Media and Ribbon Sensor Sensitivity Adjustment 63 

Troubleshooting 65 

Specifications 71 

Printer Specifications 71 

Printing Considerations 71 

Print Speeds 71 

Media Handling 72 

Media 72 

Ribbon 73 

Zebra Programming Language II (ZPL II®) 73 

Bar Codes 73 

Standard Fonts 74 

Physical 76 

Electrical 76 

Communications Interface 77 

Environmental Ranges 77 

Options and Accessories 77 

Options 79 

Peel-Off 79 

Cutter Module 79 

Media Rewind 79 

Fanfold Supply Bin 80 

External ZebraNet™ (Ethernet) Interface 80 

Black Mark (Reflective) Sensor 80 

Optional Printer Fonts 81 

230 VAC Factory Setup 82 

512 KB DRAM Memory Expansion 82 

12-Dot/mm and 6-dot/mm Printhead 82 



Zebra S-Series User's Guide vi 



Appendix 83 

230 VAC Power Cord 83 

ASCII Code Chart 84 

Adjusting Darkness for "In-Spec" Bar Codes 85 

Label Darkness Levels 86 

Optional Printer Fonts 88 

Glossary 91 

Index 95 



Zebra S-Series User's Guide vii 




iaSk** 



Zebra S-Series User's Guide 



vin 



Introduction 



Scope 



This user's guide contains descriptive information and operational 
instructions for the Zebra 105.Se and the 1605 thermal transfer demand 
printers. It contains information on how to set up and operate the printer 
as well as adjustment and maintenance procedures that can be performed 
by the operator. Information covering the use and operation of Zebra 
S-Series Printer options is also included. 

Additional documentation for the Zebra S-Series Printer is available: 

• The ZPL II® Programming Guide (part # 46469L). 

• The two-volume Maintenance Manual: Volume 1: General 
Maintenance (part # 38452L) contains the information you need to 
maintain your printer. Volume 2: Circuit Descriptions and Electrical 
Schematics (part # 38453L) contains the information you need to repair 
the circuit boards at the component level. You may order both volumes 
asaset(part#31452L). 

Model Designation 

Labels located inside the media compartment above the frame support at 
the rear of the S-Series Printer include both the serial number and model 
designation. If you need to contact our technical support staff for 
assistance, please have both the model designation and serial number 
available so that we may help you more efficiently. 



Zebra S- Series User's Guide 



System Overview 



The S-Series Printer, when connected to an appropriate ASCII data source, 
functions as a complete label, ticket, and tag printing system. Customer- 
supplied asynchronous modems may be used to connect remote hosts to 
the S-Series Printer. 

Connection of the S-Series Printer to data sources using data codes other 
than ASCII requires the use of an appropriate protocol converter. 

Connection to data sources using interfaces other than the type installed in 
the printer requires the use of an appropriate interface converter. 

Communication Capabilities 

The S-Series Printer comes with either an Electronics Industries 
Association (EIA) RS-232 serial data interface or a factory-installed 
parallel interface. In both cases, the required interface cable is not 
supplied with the printer. 

Thermal Transfer Printer Internal Functions 

Command/control data signals are received via the RS-232 port, parallel 
port, or DIP switches and are sent to the main logic board. The 
microprocessor continuously monitors these signals along with the inputs 
received from the control panel and various sensors. The microprocessor 
interprets this information and controls the S-Series Printer's mechanics, 
printhead, communications, command interpretation, label formatting, 
media control, and mechanical drive. 

Print Mechanism Capabilities 

The print mechanism has been designed to print random information 
labels, tickets, and tags. It uses a thermal printhead that heats a ribbon as it 
passes beneath the print elements, melting its ink onto the media (direct 
thermal uses heat- sensitive media instead of an inked ribbon). Constant 
print speeds may be selected via software control. 



Zebra S- Series User's Guide 



The standard printhead for the S-Series Printer has a print resolution of 
8 dots/mm (203.2 dots/inch). Optional printheads are available for the 
l05Se for either 6 dots/mm (152 dots/inch) or 12 dots/mm (300 dots/inch) 
resolution. 

Media Transport Mechanism Capabilities 

The media transport mechanism of the S-Series Printer has been designed 
to accommodate various types of media, including die-cut labels, ticket 
and tag stock, continuous roll, and fanfold media. 

Media may be rewound internally onto standard 3 " cores if the rewind 
spindle option is installed. With the peel-off option, backing material may 
be rewound internally. 

Ribbons for the S-Series Printer are supplied on 1" cores in standard 
widths and lengths. 

Additional System Requirements 

In addition to the Zebra S-Series Printer, you need the following items to 
form a complete label preparation system: 

• Label, ticket, or tag stock. 

• An intelligent device, such as a computer, for data entry or entry of ZPL 
II formats. 

• A data communication cable to connect the controlling device to the 
printer (remote installations may require additional cables and 
communication devices, such as modems and/or protocol converters). 

• Thermal transfer ribbon (if using thermal transfer mode). 



Zebra S- Series User's Guide 



Media and Ribbon Requirements 

Print quality not only depends on the Zebra S-Series Printer, but also on 
the print media. Factors such as reflectivity and contrast are important for 
bar code scanning applications. Factors such as paper abrasion and 
temperature requirements are important in maintaining the life of the 
printhead. 

We STRONGLY RECOMMEND the use of Zebra-brand media for 
continuous high quality printing. A wide range of paper, polypropylene, 
polyester, and vinyl stock has been specifically engineered to enhance the 
printing capabilities of the printer and to ensure against premature 
printhead wear. 

Continuous roll form paper, fanfold media, or cardstock with optional 
perforations and registration holes may be used. The standard 1605 
Printer and l05Se Printer with an optional reflective sensor can use 
"black-mark media" (media having a black mark printed on the liner side 
for use in positioning the labels). 

Since print quality is affected by media and ribbon, printing speeds, and 
printer operating modes, it is very important to run tests for your 
applications. This is especially true if you're operating in peel-off mode, 
where these variables combine with label size, backing content, diecut 
depth, and even humidity to affect printer operation. 

Warnings and Precautions 

Installation 

CAUTION: To ensure that the Zebra S-Series Printer has proper 
cooling, do not place any padding or cushioning material on the 
back of, or underneath, the unit. 

230 VAC Operation 

CAUTION : Refer to page 1 for instructions on configuring your 
printer for 230 VAC operation before connecting to a 230 VAC 
power source. 



Zebra S- Series User's Guide 



Use of Shielded Cable 

CAUTION: Refer to "Interconnections" on page 45. 

Zebra printers comply with FCC "Rules and Regulations", Part 1 5, 
Subpart J, for Class A Equipment, using fully shielded data 
cables. Use of unshielded cables may increase radiated 
emissions above the Class A limits and is not recommended. 

Zebra printers comply with international regulations governing 
radiated emissions when using fully shielded data cables. Use of 
unshielded cables may increase radiated emissions above the 
regulated limits. 

Ribbons and Printhead Wear 

CAUTION: Ribbons used in the Zebra Technologies Corporation 
Printer MUST be as wide as or wider than the media. 
Zebra-brand ribbons provide an extremely smooth backing 
surface that protects the printhead from abrasion by the media. 
If the ribbon is narrower than the media, areas of the printhead 
are unprotected and subject to premature wear. 



Repacking 



CAUTION: If shipment of your printer is necessary, carefully 
pack the printer in a suitable container to avoid damage during 
transit. Whenever possible, use the original container from the 
factory. If the original container is not available, an optional 
packing kit can be purchased from Zebra. When using a different 
container, a procedure similar to the original factory packaging 
should be followed. 

Refer to "Storage and Reshipping" on page 8 for further 
repacking instructions. 



Zebra S- Series User's Guide 




iaSk** 



Zebra S- Series User's Guide 



Installation 



Unpacking 

When unpacking the Zebra S-Series Printer, make sure you save all 
packing materials. Once the printer is out of the box, raise the printer's 
media access door and remove the power cord. 

Inspection 

Inspect the printer for possible damage incurred during shipment. 

• Check all exterior surfaces for damage. 

• Raise the media access door and inspect compartment for damage to 
components. 

Reporting Damage 

If you discover shipping damage upon inspection: 

• Immediately notify the shipping company of the damage. 

• Retain all packaging material for shipping company inspection. 

• File a damage report with the shipping company and notify your local 
distributor and Zebra Technologies Corporation of the damage. Zebra 
Technologies Corporation is not responsible for any damage incurred 
during shipment of the equipment and will not repair this damage under 
warranty. Immediate notification of damage to the shipping company 
or its insuring agency generally results in ensuring any damage claim 
validity and ultimate monetary compensation. 



Zebra S- Series User's Guide 



Storage and Reshipping 

If you are not placing the printer into operation immediately, repackage it 
using the original packing materials. The S-Series Printer may be stored 
under the following conditions: 

• Temperature: -40° to +158° F (-40° to +70° C) 

• Relative humidity: 20% to 85% non-condensing 

Should it become necessary to ship your printer, remove any ribbon and 
paper roll from the supply spools, otherwise damage to the printer could 
result. Carefully pack the printer in a suitable container to avoid damage 
during transit. Whenever possible, use the original container and 
packaging material from the factory. If you use a different container, a 
procedure similar to the original factory packaging should be followed. 

CAUTION: Do not package the printer in a rigid container 
without utilizing shock mounts or shock-absorbing packing 
material. A rigid container allows shock on the outside to be 
transmitted undamped to the unit, which may cause damage. 

Power Connection 

AC Voltage Selection Procedure 

The 5-Series Printer's AC voltage may be set for either 115 VAC or 230 
VAC operation. To match the printer's power entry selection to the 
available power source, refer to Figure 1 and follow the procedure outlined 
below: 

1 . Locate the AC power area at the rear of the printer. 

2. Using a small flatblade screwdriver or similar tool, move the voltage 
selection switch to the 115 V or 230 V position as required. (The 
initial position of the switch depends on how the printer was ordered.) 
Make sure that the appropriate fuse is in place. 



Zebra S- Series User's Guide 



H 



Voltage Selection Switch 

AC Power Fuse Replacement 
— AC Power On/Off Switch 



-AC Power Cable Connection 



Figure 1 



AC Power Fuse Replacement 



A user-replaceable AC power fuse is located just above the power 
ON/OFF switch (see Figure 1). For a 115 VAC installation, the 
replacement fuse is a 3AG Fast Blow style rated at 5 Amp/250VAC. For a 
230 VAC installation, the fuse is the same style but rated at 3 Amp/250 
VAC. Make sure the fuse you use is correct for the voltage source. 

Note: Before replacing the fuse, turn the AC power switch OFF and 
unplug the AC power cable. 

1 . To replace the fuse, insert the tip of a flatblade screwdriver into the 
slot in the end of the fuse holder end cap. 

2. Press in slightly on the end cap and turn the screwdriver slightly 
counterclockwise. This disengages the end cap from the fuse holder 
and allows you to remove the fuse. 

3. To install a new fuse, remove the old fuse and insert the new fuse into 
the fuse holder. 

4. Push the end cap in slightly, then insert the tip of a flatblade 
screwdriver into the slot in the end cap and turn clockwise to engage it. 



Zebra S- Series User's Guide 



115 VAC Operation 

1. Confirm that the voltage selector switch is set to 115 V. 

2. Attach the supplied power cord to the AC power receptacle located on 
the rear of the printer. 

3. Connect the opposite end of the power cord to a properly grounded 
source of 115 VAC (50 or 60 Hz) power rated for at least 5 Amps. 

230 VAC Operation 

1. Confirm that the voltage selector switch is set to 230 V. 

2. Depending on how the printer was ordered, a power cord may or may 
not be provided for 230 VAC operation. If not provided, obtain a cord 
set with the proper AC power plug. The cord may then be connected 
to the standard (international) IEC-type 3 -prong AC connector 
provided on the S-Series Printer. Refer to "230 VAC Power Cord" on 
page 83 for more information. 

Site Requirements 

CAUTION: To ensure that the S-Series Printer has proper 
ventilation and cooling, do not place any padding or cushioning 
material on the back of or underneath the unit as this restricts the 
air flow. 

The S-Series Printer may be installed on any solid, level surface of 
sufficient size and strength to accommodate the unit. The area in which 
the printer operates must meet the environmental conditions specified (see 
page 77). 

Since the Zebra S-Series Printer was designed and is fabricated as an 
industrial-type unit, it functions satisfactorily in areas such as a warehouse 
or factory floor that conform to the specified environmental and electrical 
conditions (see page 76). 



10 Zebra S- Series User's Guide 



Ribbon Loading (105Se) 

Refer to Figure 4 throughout this procedure. 



Note: When placing the ribbon roll on the ribbon supply spindle, make 
sure that the core is pushed up against the stop on the ribbon 
supply spindle and that the ribbon is aligned squarely with its 
core. If this is not done, the ribbon may not cover the inside edge 
of the printhead, exposing print elements to potentially damaging 
contact with the media. 

Do not load ribbon if the printer is to be used in the direct thermal 
mode. 

CAUTION: Do not use ribbon that is narrower than the media. If 
the printhead is not protected by the smooth backing of the 
ribbon, excessive abrasion may cause premature printhead 
failure. 

1. Align the segments of the ribbon supply spindle. See Figure 2. 




Figure 2 

2. Place the ribbon roll on the ribbon supply spindle. 

3. Open the printhead by moving the handle to the OPEN position. 



Zebra S- Series User's Guide 



11 



4. Important.. .To make ribbon loading and unloading easier, make a 
leader for your ribbon roll if it doesn't already have one (refer to 
Figure 3). Tear off a strip of media (labels and backing) about 6" - 12" 
long from the roll. Peel off a label from this strip and remove the 
remaining labels. Apply half of this label to the end of the strip and 
the other half to the end of the ribbon. This acts as a ribbon leader. 



Ribbon 



Label 




Figure 3 

5. Thread the leader and attached ribbon as shown in Figure 4. Be 
careful not to crease or wrinkle the ribbon. 

6. Remove the hook from the ribbon take-up spindle. 

7. Place the leader under the long leg of the hook and wind for several 
turns. 

8. Close the printhead by moving the lever to the CLOSED position. 



12 



Zebra S- Series User's Guide 



Ribbon Supply 
Spindle 




Lower Roller 
Upper Roller 



105Se 



Ribbon Take-up^ 
Spindle 



Ribbon Supply s 
Spindle 




Ribbon Guide 
Rollers 



160S 



Figure 4 



Zebra S- Series User's Guide 



13 



Ribbon Loading (1605) 

Refer to Figure 4 throughout this procedure. 

Note: When placing the ribbon roll on the ribbon supply spindle, make 
sure that the core is pushed up against the stop on the ribbon 
supply spindle and that the ribbon is aligned squarely with its 
core. If this is not done, the ribbon may not cover the inside edge 
of the printhead, exposing print elements to potentially damaging 
contact with the media. 

Do not load ribbon if the printer is to be used in the direct thermal 
mode. 

CAUTION: Do not use ribbon that is narrower than the media. 
If the printhead is not protected by the smooth backing of the 
ribbon, excessive abrasion may cause premature printhead 
failure. 

1. Align the segments of the ribbon supply spindle. See Figure 2. 

2. Place the ribbon roll on the ribbon supply spindle. 

3. Open the printhead by moving the handle to the OPEN position. 

4. Important...To make ribbon loading and unloading easier, make a 
leader for your ribbon roll if it doesn't already have one (refer to 
Figure 3). Tear off a strip of media (labels and backing) about 6" - 12" 
long from the roll. Peel off a label from this strip and remove the 
remaining labels. Apply half of this label to the end of the strip and 
the other half to the end of the ribbon. This acts as a ribbon leader. 

5. Thread the leader and attached ribbon as shown in Figure 4. Be 
careful not to crease or wrinkle the ribbon. 

6. Place the leader around the ribbon take-up spindle and wind 
counterclockwise for several turns. 

7. Close the printhead by moving the lever to the CLOSED position. 



14 Zebra S- Series User's Guide 



Media Loading 



To load media, move the printhead locking lever to the OPEN position. 
Refer to Figures 5, 6, 7, and 8. When the media is loaded, close the 
printhead by moving the lever on the upper printhead mechanism to the 
CLOSED position. 

Note: The first time you load media and whenever you subsequently 
change the media type, you must re-calibrate the printer. See 
"Calibration" on page 43 for details. 



Roll Media 



Roll media may contain labels of a fixed length with gaps in between or it 
may be formed as one continuous length with no gaps (see "Continuous 
Media" on page 91 for a complete definition). Both types of roll media 
mount inside the printer in the same manner. To load roll media, refer to 
Figures 5 and/or 6 and do the following: 

1 . Move the media guide and media supply guide as far away from the 
printer frame as possible. 

2. Place the media roll on the media supply hanger. 

3. Push the media supply guide inward until it is just touching the outer 
side of the media supply roll. (The guide must not cause pressure or 
excessive drag on the media supply roll.) 

4. Thread the media through the printhead as shown in the illustrations. 

5. Adjust the media guide until it just touches the outer edge of the media 
without causing it to buckle. 

6. Close the printhead by moving the lever located on the upper 
printhead assembly to the CLOSED position. 



Zebra S- Series User's Guide 15 



TEAR-OFF 



PEEL-OFF 



REWIND 



CUTTER 




TEAR-OFF 



105Se 

PEEL-OFF 



REWIND 




160S 



Figure 5 



Media Media 
Supply Su | 

Guide / Media 

Supply 

Hanger 




Platen \n 
Roller 



Spindle 
Hook 



Figure 6 



16 



Zebra S- Series User's Guide 



Tear-Off Mode 

Follow the instructions described in "Roll Media" on page 15. 

Rewind Mode 

Note: Rewind option required. 

To initially configure the printer for this mode, follow these steps: 

1 . Remove the media rewind plate from its storage location in front of 
the printhead inside the media compartment. 

2. Invert the rewind plate so that the lip on the attached hook plate points 
down. 

3. Insert the hook plate lip a short distance (1/2") into the lower opening 
in the side plate. 

4. Align the upper end of the rewind plate with the corresponding 
opening in the side plate and slide the rewind plate in so that it stops 
against the main frame. 

5. Remove the hook from the take-up spindle shaft. 

6. Route the media as shown in Figures 5 and 6 and wind it 1-2 times 
around a 3" core. 

Peel-Off Mode 

1 . Remove the rewind plate if one is present and store it on the two 
mounting screws on the inside of the front panel. Align the notch or 
web in the media so that the take label sensor can sense a peeled label. 

2. Load media as shown in Figures 5 and 6. 

3. Remove the hook from the take-up spindle shaft. 

4. Remove several labels from the media backing and then wind the 
backing 1-2 times around the media take-up spindle and reinstall the 
hook. 



Zebra S- Series User's Guide 17 



Cutter Mode 



Follow the instructions described in "Roll Media" on page 15 with the 
exception of step 6: first route the media through the cutter module (see 
Figures 5 and 6) and then close the printhead assembly by moving the 
lever located on the upper printhead assembly to the CLOSED position. 



Fanfold Media 



To load fanfold media, place the fanfold media in the bottom or to the rear 
of the media compartment or fanfold supply bin (105.Se only) and thread it 
through the printhead as shown in Figures 7 and 8. Adjust the media guide 
using the thumb screw to keep the media from drifting left or right. 

Fanfold media from outside the printer feeds through one of the two access 
slots: one at the bottom of the printer, and one at the rear. 



TEAR-OFF 



BOTTOM SUPPLY 






<§>® 


A 


=■ \o/ 




r 



REAR SUPPLY 



CUTTER 





Figure 7 



18 



Zebra S- Series User's Guide 



INTERNAL SUPPLY 



BOTTOM SUPPLY 



REAR SUPPLY 





Q^* 


B® 


& 




\Sl 




I 





^^^ 


@® 


& 




\2l 




f 




Figure 8 

Removing Used Ribbon (105Se) 

To remove used ribbon, refer to Figure 9 and follow the steps below. 

1 . Pull the hook out slightly, then rotate the hook back-and-forth several 
times as shown and remove it from the spindle. 

2. Grasp the used ribbon and remove it from the ribbon take-up spindle. 

3. Remove the empty core from the ribbon supply spindle. 

4. Follow the ribbon loading procedure on page 11 to load the new 
ribbon. 




Figure 9 



Zebra S- Series User's Guide 



19 



Removing Used Ribbon (160S) 

Refer to Figure 10. 

1. Turn the knob at the end of the ribbon take-up spindle (1) clockwise 
until it stops. This causes the ribbon release bars to pivot down (2), 
easing the spindle's "grip" on the wound ribbon. 

2. Slide the ribbon off of the ribbon take-up spindle. Once the used 
ribbon has been removed, ensure that the arrow on the knob aligns 
with the indented notch in the ribbon take-up spindle (see inset). 

3. Remove the empty core from the ribbon supply spindle. 

4. Follow the ribbon loading procedure on page 14 to load the new 
ribbon. 





y ^^v 




LJJL 





Figure 10 



20 



Zebra S- Series User's Guide 



Initial Printer Power Up 

After you finish loading the ribbon and media, continue reading through 
"Operation" beginning on page 23 and "Configuration and Calibration" 
beginning on page 39. Perform the following initial printer power-up 
steps as you come to them: 

1 . Power-On Self Test (POST) 

2. Calibration 

Note: Subsequent power-ups do not necessarily require step 2 to be 
performed. 



Zebra S- Series User's Guide 21 




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22 



Zebra S- Series User's Guide 



Operation 



Operating Your Zebra S-Series Printer 

Now that your printer is ready for operation, how does it work? The Zebra 
S-Series Printer is designed to receive instructions from a host computer, 
such as an IBM-compatible PC. To create a label, you either need to use 
label design software or write a format in ZPL II R , which is a 
programming language for creating label formats. If you are using label 
design software, refer to the instructions provided with your software 
package to determine how to proceed. 

If you are using, or plan to use, ZPL II, make sure you have a copy of the 
ZPL II Programming Guide. This guide is available by contacting your 
distributor or Zebra Technologies Corporation. For some sample ZPL II 
label formats, see page 35. But first, we'll describe the different operating 
modes. 

Printer Operating Modes 

The S-Series Printer can be configured for several different modes of 
operation by sending the proper commands from the host computer. 
Operating modes may also be configured via a bank of DIP switches at the 
rear of the printer. (See "Option Switches" on page 39 for more 
information about DIP switches.) 

Media Sensing Modes 

There are two basic modes by which the printer can sense the position of 
the media: transmissive sensing mode and black mark sensing mode. The 
1605 comes standard with both transmissive sensing mode and black mark 
sensing mode capabilities. The l05Se comes standard with transmissive 
sensing mode capability, but may be factory ordered with an additional 
black mark sensor. 



Zebra S- Series User's Guide 23 



Transmissive Sensing Mode 

In transmissive sensing mode, a sensor detects a light shining through a 
web, notch, or hole in non-continuous media. In this way, the printer 
determines the position of the label/tag. 

Black Mark Sensing Mode 

In black mark sensing mode, a sensor detects the black marks that are 
printed on the back of the label liner for each label. The label length and 
top of label are determined by the location of the black mark. 

Media Transport Modes 

Tear-Off Mode 

When the media is in the rest (idle) position, the webbing between labels is 
over the tear-off/peel-off bar. To print a label, the printer first backfeeds 
the media until the start of the label is directly under the printhead and then 
prints the entire label. 

After a label is printed, the media feeds forward until the end of the label is 
past the tear-off/peel-off bar. This label position is determined by 
commands sent to the printer from the host computer or by front panel 
adjustments. 

When a quantity of labels is required, a format for printing a batch of 
labels can be sent to the printer. Once a label is printed, the media feeds 
forward to the start of the next label and printing continues. In this way, 
the printer prints the batch and stops when it reaches the quantity required. 

When a quantity of individual labels is required, the format for printing a 
batch of labels can still be sent to the printer. The operator can use the 
PAUSE key to cycle the printing one label at a time. The operator can then 
tear off each label before printing the next one. 



24 Zebra S- Series User's Guide 



Peel-Off Mode 



When the media is in the rest (idle) position, the start of the label to be 
printed is slightly in front of the printhead. To print a label, the printer first 
backfeeds the media until the start of the label is directly under the 
printhead and then prints the entire label. 

In this mode, once the label is printed, the media passes over the tear-off/ 
peel-off bar at an extremely sharp angle. The backing material is peeled 
away from the label and winds around the peel-off spindle or the media 
rewind spindle. The media feeds forward until most of the label hangs 
loose from the backing. The label is held in this position by that portion of 
the backing that has not crossed the tear-off/peel-off bar. 

The label available sensor is activated by the label. When the operator 
removes the label, the printer backfeeds the media either to the rest (idle) 
position or to the printing position and prints the next label. 

Note: You do not need to turn the printer OFF when it is necessary to 
remove the media backing from the take-up spindle. 

Rewind Mode 

Some applications call for the media to be rewound onto a core as the 
labels are printed. 

When the media is in the rest (idle) position, the start of the next label is 
directly under the printhead. After the label is printed, the media feeds 
forward until the start of the next label is under the printhead. The media 
never backfeeds in this mode. 

When the printer completes a batch of labels, printing stops. 

Cutter Mode 

In this mode the cutter, under software control, automatically cuts 
individual labels (or at the end of batches of labels) after printing. The 
optional cutter catch tray gathers the completed labels. 



Zebra S- Series User's Guide 25 



Front Panel Keys 



PAUSE Key 



The PAUSE key stops and restarts the 
printing process. If the printer is idle 
(not printing) when the PAUSE key is 
pressed, no printing can occur. If the 
PAUSE key is pressed while printing is 
in progress, the printing stops once the 
current label is complete. Pressing the 
PAUSE key a second time resumes the 
printing process. 



FEED Key 



The FEED key forces the printer to feed 
one blank label. If the printer is idle, or 
if the PAUSE function is active when 
the FEED key is pressed, one blank 
label feeds from the printer 
immediately. If the printer is printing, 
then one blank label feeds out after 
completion of the current batch of 
labels. After one blank label feeds out, 
pressing FEED again provides another 
blank label. 



CANCEL Key 



)) /( } POWER 



))WML 



PRINTHEAD 



PAPER/RIBBON 



PAUSE 



FEED 




DATA 



CANCEL 

}) © ZX 7 DARKEN 
')')■#> /XU 7 POSITION 
))°H A CALIBRATE 

MODE 



§ 



Figure 11 



The CANCEL key is only recognized in PAUSE mode. Press CANCEL to 
cancel the current label format. If no format is printing, then the next one 
to be printed is canceled. If no formats are in memory, the CANCEL key 
is ignored. If the CANCEL key is pressed for an extended period of time 
(3 seconds), the printer cancels all formats in memory and the DATA light 
turns OFF. 



26 



Zebra S- Series User's Guide 



MODE Key 

The MODE key puts the printer in configuration mode. In this mode, you 
can adjust the print darkness, media tear-off position, and label top 
position, or perform a calibration. See "Configuration and Calibration" 
beginning on page 39 for more information. 

Front Panel Lights 

Refer to Figure 11 for the location of the lights. 

Note: If an operating condition which causes a light to be ON 

constantly and one which causes the same light to flash occur 
simultaneously, the light flashes. 



Indicator Light Name 


Status 


Indication 


POWER 


ON 


Printer is on. 


PRINTHEAD 


OFF 


Normal operation 


ON 


Head Over Temperature condition. Printing stops until the 
printhead cools down. Printing resumes automatically. 


Printhead Under Temperature condition. Printing 
continues. 


Power Supply Over Temperature condition. Printing stops 
until the power supply cools down. Printing resumes 
automatically. 


Flashing 


Printhead Open. 


PAPER/RIBBON 


OFF 


Media and ribbon (if used) are properly loaded. 


ON 


Paper out. 


Flashing 


1 . In Thermal Transfer Mode: Ribbon is out. 


2. In Direct Thermal Mode: Ribbon is in the printer. 


PAUSE 


OFF 


Normal operation. 


ON 


Printer has stopped all printing operations. 


DATA 


OFF 


Normal operation. 


ON 


Labels are printing. 


Single Flash 


The CANCEL key was pressed and a format was 
successfully deleted from the print queue. 


Flashing 


Receiving data from host computer. 


Slow Flashing 


Printer sent a "stop transmitting" command to the host 
computer. 


DARKEN 


ON 


Printer is in the Configuration Mode. See page 42 for 
more information. 


POSITION 


ON 


CALIBRATE 


ON 



Zebra S- Series User's Guide 



27 



Power-On Self Test 

A Power-On Self Test (POST) is performed each time the printer is turned 
ON. This test checks for proper initialization of various electronic circuits 
and establishes starting parameters as those stored in the printer's memory. 
During this test sequence, the front panel lights turn ON and OFF to ensure 
proper operation. At the end of this self test, only the POWER light 
remains lit. If other lights are also lit, refer to "Troubleshooting" 
beginning on page 65. 

Printer Self Tests 

Introduction 

These self tests produce sample labels and provide specific information 
that helps determine the operating conditions for the printer. 

Each self test is enabled by holding in a specific front panel key or 
combination of keys while turning the power switch ON. Keep the key 
depressed until the front panel lights turn ON. 

When the Power-On Self Test is completed, the selected self test 
automatically starts. 

Note: When performing self tests, all data interface cables connected to 
the rear of the printer must be removed. 

When canceling a self test before its actual completion, always 
turn the printer power OFF and then back ON to reset the printer. 

When performing these self tests in the peel-off mode, the 
operator must remove the labels as they become available. 

Unless specifically stated, all tests print in tear-off mode in tear- 
off printers and in peel-off mode for peel and rewind printers. 

If your media is not wide enough, the test labels only print out to 
the edge of the label. If your media is too short, the test label 
continues printing on the next label. 



28 Zebra S-Series User's Guide 



Some of the printer self tests produce labels at varying print speeds. These 
speeds may be referred to as "inches per second," "millimeters per 
second," or by alphabetic letter designation (i.e., "A," "B," "C," etc.). The 
following chart shows the relationships between the different speeds: 



Letter Designation 


English 


Metric 


A* 


27sec. 


51 mm/sec. 


B 


3"/sec. 


76 mm/sec. 


C 


4"/sec. 


102 mm/sec. 




5"/sec. 


127 mm/sec. 


D 


6"/sec. 


152 mm/sec. 



* Speed "A" for the 105.Se with the optional 300 dots-per-inch printhead is 
2.4" (61 mm). 



Zebra S- Series User's Guide 



29 



CANCEL Key Self Test 



This self test prints a single label which contains a listing of the printer's 
current configuration parameters stored in configuration (EEPROM) 
memory. Press the CANCEL key while turning the AC power switch ON. 
See Figure 12 for a sample configuration printout. 



PRINTER CONFIGURATION 


+30 


.. DARKNESS 


+0 


. . TEAR OFF 


CUTTER 


. . PRINT MODE 


NON-CONTINUOUS... 


. . MEDIA TYPE 


MARK 


. . SENSOR TYPE 


THERMAL-TRANS.... 


. . PRINT METHOD 


104 0/8 MM 


.. PRINT WIDTH 


1230 


. . LABEL LENGTH 


39.0IN 988MM... 


. . MAXIMUM LENGTH 


MAIN RS232 


.. HOST PORT 


NONE 


. . Z-NET PORT 


1S200 


.. BAUD 


8 BITS 


.. DATA BITS 


NONE 


.. PARITY 


1 STOP BIT 


.. STOP BITS 


XON/XOFF 


. . HOST HANDSHAKE 


NONE 


.. PROTOCOL 


000 


.. NETWORK ID 


NORMAL MODE 


.. COMMUNICATIONS 


< > 7EH 


. . CONTROL PREFIX 


< A > 5EH 


. . FORMAT PREFIX 


<,> 2CH 


.. DELIMITER CHAR 


FEED 


. . MEDIA POWER UP 


FEED 


. . HEAD CLOSE 


DEFAULT 


.. BACKFEED 


+000 


. . LABEL TOP 


+0000 


.. LEFT POSITION 


038 


.. WEB S. 


075 


.. MEDIA S. 


058 


.. RIBBON S. 


092 


.. MARK S. 


092 


.. MARK MED S. 


000 


.. MEDIA LED 


000 


.. RIBBON LED 


000 


.. MARK LED 


DPCS 


. . MODES ENABLED 




.. MODES DISABLED 


832 8/MM FULL.... 


.. RESOLUTION 




.. SOCKET 1 ID 




.. SOCKET 2 ID 


V21.X.X 


.. FIRMWARE 


CUSTOMIZED 


.. CONFIGURATION 


1024k 


.. MEMORY 


NONE 


.. B= MEMORY 



FIRMWARE IN THIS PRINTER IS COPYRIGHTED 



The configuration may be changed 
either temporarily (for specific label 
formats or ribbon and label stock), or 
permanently (by saving the new 
parameters in EEPROM Memory). 
Saving new parameters occurs 
whenever a printer calibration 
procedure is performed. For more 
details, refer to "Calibration" on 
page 43. 



Figure 12 



30 



Zebra S- Series User's Guide 



PAUSE Key Self Test 



This self test is actually comprised of four individual test features, as 
described below. 

1. The initial self test prints 15 labels at speed "A" then automatically 
PAUSES the printer. When the PAUSE key is pressed, an additional 
15 labels print out. 

2. While the printer is PAUSED, pressing the CANCEL key once alters 
the self test. When the PAUSE key is pressed, the printer prints 15 
labels at speed "D" ("C" for the 300 dpi ). 

3. While the printer is PAUSED, pressing the CANCEL key a second 
time alters the self test again. When the PAUSE key is pressed, the 
printer prints 50 labels at speed "A." 

4. While the printer is PAUSED, pressing the CANCEL key once alters 
the self test a third time. When the PAUSE key is pressed, the printer 
prints 50 labels at speed "D" ("C" for the 300 dpi ). 

Note: On printers with either the rewind or peel option installed, the 
peel mode is activated during the first half (steps 1^1) of the 
PAUSE Key Self Test. On printers with a rewind option, the 
rewind plate must be removed for proper function of the peel 
sensors during the test. The first label to print says, "PEEL 
OPTION INSTALLED." Each label must be manually removed 
from the sensor path before the next label prints. Steps 1^1 are 
then repeated in rewind mode. 

This self test can be used to provide the test printouts required when 
making adjustments to the printer's mechanical assemblies. See the 
sample printout in Figure 13. 



234567890 12345678901 234567890 123456789012345678901234567898 1234567 




Figure 13 



Zebra S- Series User's Guide 



31 



FEED Key Self Test 



Note: The CANCEL Key Self Test should be performed before this self 
test. Information on the configuration printout (see Figure 12 on 
page 30) can be used with the results of this self test to determine 
the best darkness setting for a specific media/ribbon combination. 

The FEED Key Self Test prints out at various darkness settings above and 
below that of the darkness value shown on the configuration label. Inspect 
these labels and determine which one has the best darkness setting for the 
application. This value can be entered into the printer by setting the 
darkness during the configuration procedure. 

The value printed on the FEED 
Key Self Test label is added to 
(plus) or subtracted from 
(minus) the "Darkness" value 
specified on the configuration 
label. The resulting numeric 
value (0 to 30) is the best 
darkness value for that specific 
media/ribbon combination. 



The darkness value can also be 
programmed into the ZPL II 
formats sent to the printer. 




Figure 14 



32 



Zebra S- Series User's Guide 



FEED Key and PAUSE Key Self Test 

Pressing these two keys at the same time, while turning the power ON, 
temporarily resets the printer configuration to the factory default values. 
These values remain active until power is turned OFF. Whenever the 
printer is reset to factory defaults, a media calibration procedure must 
be performed immediately. See page 43 for details. 

MODE Key Self Test 

This test places the printer in the communications diagnostics mode. In 
this mode, the printer prints the ASCII characters and their corresponding 
hexadecimal values for any data received from the host computer. A 
typical printout from this test is shown in Figure 15. 

Note: This label is inverted when printed. 



/V FS /V F03 < ?4 , 25^AA 

5E 46 53 5E 46 4F 33 39 34 2C 32 35 5E 41 41 

N, 18, 1 0^FDC0000 

4E 2C 31 38 2C 31 30 5E 46 44 28 30 30 30 30 

)999-9999^FS 

29 39 39 39 2D 39 39 39 39 5E 46 53 0D 0A 

^FO0 , 50^AAN ,18, 

5E 46 4F 38 2C 35 39 5E 41 41 4E 2C 31 38 2C 

1 0^FDCENTER STA 

31 30 5E 46 44 43 45 4E 54 45 52 20 53 54 41 



Figure 15 

PAUSE Key and CANCEL Key Self Test 

This test prints a maximum of 500 head test labels. Each label backfeeds 
prior to printing and feeds forward to the rest position after printing. A 
serialized number prints on each label. Press the PAUSE key or turn the 
printer power OFF to stop printing. The labels look like the one in Figure 
13 except that a serialized number prints on each label. 



Zebra S- Series User's Guide 



33 



FEED Key and CANCEL Key Self Test 

This test prints seven pre-programmed label formats at different speeds. 
The printer automatically pauses after each format. The sequence of label 
formats is as follows: 



Label Format 


Quantity 


Inches per 
second 


Left Ribbon Wrinkle Test 


20 


D* 


Right Ribbon Wrinkle Test 


20 


D* 


C39 Wrinkle Test 


20 


D* 


Left Ribbon Wrinkle Test 


20 


A 


Right Ribbon Wrinkle Test 


20 


A 


C39 Wrinkle Test 


20 


A 


Usable Area Test 


10 


D* 


Head Temperature Test 


10 


D* 


Upper Smear Test 


10 


D* 


Lower Smear Test 


10 


D* 


Usable Area Test 


10 


A 


Head Temperature Test 


10 


A 


Upper Smear Test 


10 


A 


Lower Smear Test 


10 


A 



* "C" for the l05Se with the 300 dots/inch printhead. 

Extended Printer Diagnostics 

Extended diagnostic tests are available. The maintenance manual, Vol. 1: 
General Maintenance, provides the information needed to perform these 
additional tests. 



34 



Zebra S- Series User's Guide 



I® 



Sample ZPL IP Label Formats 



ZPL II (Zebra Programming Language II) is Zebra Technologies 
Corporation's label design language. ZPL II lets you create a wide variety 
of labels from the simple to the very complex, including text, bar codes, 
and graphics. 

This section contains three sample label formats for you to begin 
experimenting with. It is not intended as an introduction to ZPL II. To 
learn about ZPL II, contact your distributor or Zebra Technologies 
Corporation for a copy of the ZPL II Programming Guide. 

For each format, do the following: 

1. Save the file. 

2. Copy the file to the printer. 

• Set up the printer and turn the power ON. 

• Use a text editing program (e.g., Windows Write or DOS Editor) 
and type in the label format exactly as shown in the sample label 
formats on pages 36-37. 

• Save the file in a directory for future use. Use the extension " . zpl". 

• Copy the file to the Zebra S-Series Printer. 

Note: Typically, computers running DOS use the "COPY" command to 
send a file to the Zebra printer. For example, if your file name is 
"formatl.zpl" then type, "COPY FORMAT1.ZPL COM1". 

3 . Compare your results with those shown. If your printout does not look 
like the one shown, confirm that the file you created is identical to the 
format shown, then repeat the printing procedure. If nothing prints, 
refer to "Installation" beginning on page 7 to make sure your system is 
set up correctly; otherwise, refer to "Troubleshooting" beginning on 
page 65. 



Zebra S-Series User's Guide 35 



Format 1: Simple Text and a Barcode 



Line# 


Type this label format: 


You'll get this printout: 


1 
2 
3 

4 
5 


A XA 

A LH30,30 

A FO20,10 A AD A FDZEBRA A FS 

A FO20,60 A B3N,Y,20,N A FDAAA001 A FS 

A XZ 


ZEBRA 

i iiiiiii inn inn mi mil mil mi mil mi 


Line#1 : Indicates start of label format. 

Line #2: Sets label home position (in dots) from the upper left-hand corner of the label. 

Line #3: Sets field origin, selects font "D", defines field data as "ZEBRA". 

Line #4: Sets field origin, selects bar code Code 39, sets barcode height at 20 dot rows, 

defines field data for bar code as "AAA001 ". 
Line #5: End of label format. 



Format 2: Saving a Label Format as a Graphic Image 



Line# 


Type this label format: 


You'll get this printout: 


1 


A XA 


(Same as Format 1 , but this format was 


2 


A LH30,30 


also saved in the printer's memory as a 


3 


A FO20,10 A AD A FDZEBRA A FS 


graphic image named "FORMAT2".) 


4 


A FO20,60 A B3N,Y,20,N A FDAAA001 A FS 




5 


A ISFORMAT2,N 




6 


A XZ 


ZEBRA 


7 


A XA 


i iiiiiii mil mil mi inn mil mi inn mi 


8 


A ILFORMAT2 




9 


A XZ 




Line#1 -4: These commands were described in Format 1 . 


Line #5: Saves the format in the printer's memory as a graphic image named "FORMAT 2", the 


"N" indicates "do not print after saving". 


Line #6-7: (See Format 1). 


Line #8: Load and print the graphic image saved as "FORMAT2". 


Line #9: (See Format 1). 



36 



Zebra S- Series User's Guide 



Format 3: Using a Serialized Data Field 



Line# 


Type this label format: 


You'll get this printout: 


1 
2 
3 
4 
5 


A XA 

A LH30,30 

A FO20,1 A AD A FDZEBRA A FS 

A FO20,60 A B3„40„ A FDAAA001 A FS 

A FO20,180 A AF A SNSERIAL NUMBER 

00000000111, 1,Y A FS 


ZEBRA 
III II I II III I II 

KAA001K 

SERIAL NUMBER 00000000111 


6 

7 


A PQ10 
A XZ 


Ten labels should print. The first 
and last are shown here. 


ZEBRA 
III II III III III 

BAA001B 

SERIAL NUMBER 00000000120 


Line #1 
Line #4 
Line #5 
Line #6 
Line #7 


3: These commands were described in Format 1 . 
Defines field data for bar code as "AAA001 ". 

Defines serialized field, starting value of 111 , increment by 1 , insert leading zeros. 
Sets print quality to 10. 
(See Format 1). 



Zebra S- Series User's Guide 



37 




iaSk** 



38 



Zebra S- Series User's Guide 



Configuration and Calibration 



Option Switches 



These switches are located at the rear of 
the printer above the Signal Interface 
Cable Connection. See Figure 16. 

In the tables on the following page, an 
"R" means the switch is OFF 
(positioned to the right), while an "L" 
means the switch is ON (positioned to 
the left). All switches are in the OFF 
position when the printer is shipped 
from the factory. 





1(L) (R) 
ON OFF 


Wr 

K 

E 


HiH 
~~ n 







Figure 16 



■ BANK 2 BANK 2 ■ 



BANK 1 

(ONLY ON 
SERIAL UNITS) 



- SIGNAL INTERFACE - 
CABLE CONNECTION 






105Se b 160S 
PARALLEL 






105Se&160S 
SERIAL 



Figure 17 



Zebra S- Series User's Guide 



39 



Bank 1 



Note: For Serial Interface 
Printers only. 

The S-Series Printer, with the 
RS-232 Serial Interface, uses eight 
miniature switches located on the 
rear of the printer above the signal 
interface cable connector. The 
ON/OFF positions of these 
switches establish some of the 
printer configuration parameters. 
Bank 1 switches must be properly 
positioned to establish serial data 
communications with the host 
computer. Thereafter, the position 
of these switches should not be 
changed. 

Note: Parallel-interface printers 
do not require these 
configuration parameters, 
therefore they have no 
Bank 1 switches. 

If these switches are in the proper 
position to match the 
communication configuration of 
the host computer, and the printer 
is not receiving data, refer to 
"RS-232 Cabling Requirements" 
on page 47 and make sure the 
correct interface cable is being 
used. 

Note: The printer is fixed at 1 
stop bit, so make sure 
that your host device is 
also set at 1 stop bit. 



Bank 1 (Serial Interface Printers Only) 


Switch 
3 2 1 


Baud 
Rate 


R 




R 


9600 baud 


R 




L 


19200 baud 


R 




R 


110 baud 


R 




L 


300 baud 


L 




R 


600 baud 


L 




L 


1200 baud 


L 




R 


2400 baud 


L 




L 


4800 baud 


Switch 


Data Bits 

(Must be set to 8 data bits to 

use Code Page 850) 




7 Data Bits 




8 Data Bits 


Switch 
6 5 


Parity 

(If you choose 7 data bits, 

you must choose either even 

or odd parity) 


R 


R 


Even parity 


R 


L 


Parity disabled 


L 


R 


Odd parity 


L 


L 


Parity disabled 


Switch 
7 


Communication 
Handshake Control 


R 


XON/XOFF control 


L 


DTR/DSR control 


Switch 
8 


Error Detection Protocol 


R 


No error detection 


L 


Error detection active 



Table 1 



40 



Zebra S- Series User's Guide 



Bank 2 



These switches can manually override any ZPL II commands that affect 
print mode, media mode, and media type. They can also override settings 
established during the calibration procedure. Reasons why you might 
want to use these override switches are: 



• Troubleshooting. By using these switches, 
you know beyond a doubt what operating 
mode your printer is in. 

• Lets you use a single ZPL II label format 
for many different printers — without 
worrying if the format contains a mode 
command that is inappropriate for your 
printer configuration. 

• Some third-party label design software 
packages work better if these switches 
control the mode. 

If you do not want to override ZPL II or the 
calibration settings, disable one or more of the 
override options by setting switches 1 , 4, 
and/or 7 to the R (OFF) position and turning 
the power ON. With these disabled, the 
printer requires ZPL II commands and/or 
re-calibration to set print mode, media mode, 
and/or media type. 



Table 2 

To override, set the switches to one of the modes shown in the table. If 
you are in the process of printing, this change takes effect on the next label 
printed. If you change the switches from active to disabled after printer 
power-up, the printer remains in the current mode until a ZPL II command 
or re-calibration changes the mode. 

Note: For the 105.Se, Switch 5 must not be positioned to the right unless 
the printer is equipped with the optional black mark sensor. 





ank2 


Switch 

3 2 1 


Print 
Mode 


R 


R 


L 


Cotter 


R 


L 


L 


Tear-Off 


L 


R 


L 


Peel-Off 


L 


L 


L 


Rewind 






R 


Override is disabled 


Switch 

6 5 4 


Media 
Mode 


R 


R 


L 


Black-mark sensing mode 


R 


L 


L 


Transmissive sensing mode 
will non-continuous media 
(detects a web/notch) 


L 


L 


L 


Transmissive sensing mode 
will continuous media 






R 


Override is disabled 


Switch 

8 7 


Media 
Type 


R 


L 


Thermal transfer 


L 


L 


Direct thermal 




R 


Override is disabled 



Zebra S- Series User's Guide 



41 



Configuration Mode 

The configuration mode allows you to fine-tune the internal printer 
configuration settings for your application. In this mode, you can change 
the following parameters: 

• Printing darkness 

• Rest position of the media with respect to the "web" or "interlabel gap" 

• Position of printing relative to the top of the label 

• Media and ribbon sensor values 

• Label length 

• Printing method 

• Media type (continuous or non-continuous) 

You can get a printout of the printer configuration (the values for each of 
these parameters) at any time by performing the CANCEL Key Self Test 
(see page 30). 

If it is ever necessary to reset the printer configuration to the factory 
defaults, refer to the "FEED Key and PAUSE Key Self Test" on page 33. 

The ZPL II Programming Guide contains information on instructions that 
may be sent to the printer to disable the MODE key and set specific label 
format values for each of these parameters. If you are not using ZPL II, 
refer to the instructions provided with your software package to determine 
if you also have this capability. 



42 Zebra S- Series User's Guide 



Calibration 



Note: Perform the calibration procedure when media and ribbon are 

first installed and each time a different type of media or ribbon is 
installed. 

During this procedure, the printer automatically determines the media 
type, label length, media and ribbon sensor settings, and printing method. 
Media type is determined by sensing either continuous or non-continuous 
media as blank labels move through the printer. If non-continuous media 
is sensed, label length is also calibrated. If ribbon is sensed, the thermal 
transfer print method is configured. If no ribbon is present, the direct 
thermal print method is configured. 

The results of this calibration are stored in the printer's memory. These 
parameters remain in effect until the next calibration is performed. The 
printer configuration printout, which prints when the CANCEL Key Self 
Test is performed, lists these results as well as other printer parameters. 

Note: If the printer is in the peel-off mode, the operator must "catch" 
the labels as they are peeled away from the backing during this 
procedure. 

1. Load media and ribbon (if used). Make sure the media sensor is 
properly positioned (see "Media and Ribbon Sensor Sensitivity 
Adjustment" on page 63). 

Note: To use the black mark sensing mode, make sure you set the Bank 
2 DIP switches appropriately (see page 41). 

2. Turn the power switch ON. When the Power-On Self Test is 
complete, the POWER, PAUSE, and PAPER/RIBBON lights are ON. 

3. Briefly press the MODE key three times. PAUSE and CALIBRATE 
lights turn ON. 

4. Press UP (FEED Key) to calibrate. The printer feeds some media. 
The MODE lights flash ON and OFF to indicate that the settings have 
been saved in memory. 

5. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF. 



Zebra S- Series User's Guide 43 



Adjusting the Print Darkness 

This procedure sets the darkness of the printing on the label. Use the 
lowest setting that provides the necessary print quality. 

1 . Press the MODE key. PAUSE and DARKEN lights turn ON. 

2. Press UP or DOWN to adjust the current setting. 

3. Press the MODE key three times. The MODE lights flash ON and 
OFF to indicate that the settings have been saved in memory. 

4. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF. 

Adjusting the Media Rest Position 

This procedure sets the end-of-label position relative to the tear-off bar or 
cutter. 

1. Briefly press the MODE key twice. PAUSE and POSITION lights 
turn ON. 

2. Press UP or DOWN to adjust the current setting. 

3. Briefly press the MODE key twice. The MODE lights flash ON and 
OFF to indicate that the settings have been saved in memory. 

4. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF. 

Adjusting the Position of the Top of the Label 

This procedure positions the printing on the label relative to the top edge 
of the label. 

1 . Briefly press the MODE key twice, then press and hold for about five 
seconds until the lights change. PAUSE, DARKEN, and 
CALIBRATE lights turn ON. 

2. Press UP or DOWN to adjust the current setting. 

3. Briefly press the MODE key twice. The MODE lights flash ON and 
OFF to indicate that the settings have been saved in memory. 

4. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF. 



44 Zebra S- Series User's Guide 



Interconnections 



System Components 




Zebra Printer 



Host 
(i.e.. Computer, etc. 



Figure 18 

System Considerations 

Communications Code 

The Zebra S-Series Printer sends and receives American Standard Code 
for Information Interchange (ASCII). This code consists of 128 characters 
(256 for Code Page 850) including upper and lower case letters, 
punctuation marks, and various control codes. 



Zebra S-Series User's Guide 



45 



Interfaces 



The method of interfacing the Zebra S-Series Printer to a data source 
depends on the communication options installed in the printer. Depending 
on how the printer was ordered, the interface is either an RS-232 serial 
data port or a parallel port. 



Data Specifications 

When communicating via the serial data port (RS-232), the baud rate, 
number of data bits, and the parity are user-selectable (see Table 1 on 
page 40 for acceptable setting combinations). Parity only applies to data 
transmitted by the printer, since it ignores the parity of received data. The 
S-Series Printer is fixed at 1 stop bit, so make sure that your host is also set 
at 1 stop bit. 

When communicating via the parallel port, the previously mentioned 
parameters are not considered. 

RS-232 Serial Data Port 

The connections for the standard interface are made through the DB-25S 
connector on the rear panel. For all RS-232 input and output signals, the 
S-Series Printer follows both the Electronics Industries Association's 
(EIA) RS-232 and the Consultative Committee for International Telegraph 
and Telephone (CCITT) V.24 standard signal level specifications. 

RS-232 Pinouts 



Pin No. 


Description 


1 


Frame Ground for Cable Shield 


2 


TXD (Transmit Data) output from the printer 


3 


RXD (Receive Data) input to the printer 


4 


RTS (Request to Send) output from the printer 


6 


DSR (Data Set Ready) input to the printer 


7 


Signal Ground 


20 


DTR (Data Terminal Ready) output from the printer 


Note: Pins 5, 8, 10-19, and 21-25 are unused and unterminated. 



Table 3 



46 Zebra S- Series User's Guide 



Hardware Control Signal Descriptions 

Request To Send (RTS) is a control signal from the S-Series Printer to the 
host computer. RTS is always in the ACTIVE condition (positive voltage) 
whenever the printer is powered ON. 

Data Set Ready (DSR) is a control signal from the host computer to the 
printer. When DSR is in the ACTIVE condition (positive voltage), the 
printer can transmit status to the host. When RTS is in the INACTIVE 
condition (negative voltage), the printer does not transmit any data. 

When DTR/DSR handshaking is selected via DIP Switch #7 at the rear of 
the printer, the Data Terminal Ready (DTR) control signal output from the 
printer controls when the host computer may send data. DTR ACTIVE 
(positive voltage), permits the host to send data. When the printer places 
DTR in the INACTIVE (negative voltage) state, the host must not send 
data. 

Note: When XON/XOFF handshaking is selected, data flow is 

controlled by the ASCII Control Codes DC1 (XON) and DC3 
(XOFF). The DTR control lead does not have an effect. 

RS-232 Cabling Requirements 

The required cable must have a 25-pin "D" Type (DB-25P) male connector 
on one end, which is plugged into the mating (DB-25S) female connector 
located at the upper rear of the printer. Tighten the locking screws. 

The other end of the signal interface cable connects to an appropriate point 
at the host computer. This cable is one of two types depending on the 
specific interface requirements. Refer to page 48 for information on the 
standard and null modem cables. 

Data cables must be fully shielded and fitted with metal or metallized 
connector shells. Shielded cables and connectors are required to prevent 
radiation and reception of electrical noise. 

To minimize electrical noise pickup in the cable: 

• Keep data cables as short as possible. 

• Do not bundle the data cables tightly with power cords. 

• Do not tie data cables to power wire conduits. 



Zebra S- Series User's Guide 47 



Interconnect to DTE Devices 





DTE 

1 
2 
3 
4 
5 
6 
7 
8 
9 








DTE 

1 
2 
3 
4 
5 
6 
7 
8 
9 




% (RD) 




(RD) ^ 


^rrm 


]^X^ 


(TDL 


> (DTR) 




(DTR) ^ 


(SG) 


~\ s ^/ / ~ 


(SG) 


< (DSR) 


^xx^ 


(DSR)^ 


k (RTS) 


1 1 


, (RTS) 













Figure 19 
Interconnect to DCE Devices 



The printer is configured as Data 
Terminal Equipment (DTE). To 
connect the printer to other DTE 
devices (such as the serial port of a 
PC), use an RS-232 Null Modem 
(crossover) cable. Figure 19 
illustrates the connections required 
for this cable. 





DCE 

1 
2 
3 
4 
5 
6 
7 
8 
9 


CARRIER DETECT (CD) w 


DTE 

1 
2 
3 
4 
5 
6 
7 
8 
9 




RECEIVE DATA (RD) > 


< TRANSMIT DATA (TD) 


< DATA TERMINAL READY (DTR) 


SIGNAL GROUND (SG) 


DATA SET READY (DSR) 


< REQUEST TO SEND (RTS) 


CLEAR TO SEND (CTS) w 





When the printer is connected via 
its RS-232 interface to Data 
Communication Equipment (DCE) 
such as a modem, use a standard 
RS-232 (straight-through) interface 
cable. Figure 20 illustrates the 
connections required for this cable. 



Figure 20 



48 



Zebra S- Series User's Guide 



Parallel Cabling Requirements 

The required cable must have a standard 36-pin parallel connector on one 
end, which is plugged into the mating connector located at the upper rear 
of the printer. The parallel interface cable is connected using bail clips, 
instead of screws, in a similar position to that of the serial data cable. 

The other end of the parallel interface cable connects to an appropriate 
point at the host computer. 

Data cables must be fully shielded and fitted with metal or metallized 
connector shells. Shielded cables and connectors are required to prevent 
radiation and reception of electrical noise. 

To minimize electrical noise pickup in the cable: 

• Keep data cables as short as possible (maximum length: 10 ft.). 

• Do not bundle the data cables tightly with power cords. 

• Do not tie data cables to power wire conduits. 

Parallel Interface 

The parallel interface provides a means of communication that is typically 
faster than the previously mentioned serial interface method. In this 
method, the bits of data which make up a character are sent all at one time 
over several wires in the cable, one bit per wire. 

Data signals are defined as either HIGH or LOW, while control signals are 
either Active or Inactive. Some control signals are active HIGH while 
others are active LOW. The voltage levels which represent these 
conditions are: 

Data Signal Voltage Level 

HIGH +5 VDC 

LOW VDC 



Zebra S- Series User's Guide 49 



Signal Descriptions 



The following chart provides a description of each of the pins in the 
parallel connector. A standard parallel data cable provides the required 
interconnection between the computer and the printer. 



Parallel Connector Pin Assignments 


Pin No. 


Description 


1 


The nStrobe printer input has internal 3.3 kW pull-up resistors to 5 V 
(I l= 1-5 mA) and is designed to receive a signal driven open collector 
V l <= 0.8 V. This pin is a signal from the host computer. The nStrobe 
input is debounced on a LOW going edge to require an active width 
greater than 0.5 ms before data is latched. 


2-9 


Data inputs have TTL input characteristics with internal 3.3 kW pullups 
and represent 1 TTL unit load or less. The data inputs are positive logic 
with a HIGH voltage level corresponding to a logic 1 . Pin 2 through Pin 
9 = DO through D7 respectively. 


10 


The nAck output is an active LOW pulse used to indicate termination. 
nAck is a driven open collector with a 3.3 kW internal pull-up. The 
output sinks 7 mA to a V |_ <= 0.4 V. 


11 


The Busy output is active HIGH whenever the printer cannot accept 
data due to any normal or abnormal condition, including buffer overflow, 
head open, over temperature, and media error conditions. Busy is a 
driven open collector with a 3.3 kW internal pull-up. The output sinks 7 
mA to a V OL <= 0.4 V. 


12 


The PError signal is active HIGH whenever the printer is out of media or 
ribbon. 


13 


The Select signal function is determined by an additional configuration 
option which becomes active when the port is present. In the default 
condition, select is active HIGH whenever the parallel port is powered 
up and the parallel port is enabled. In the non-default condition, select 
is active LOW whenever the printer is printing. 


14 


nAutoFd (not connected). 


15 


Not defined. 


16 


Logic Gnd. 


17 


FRAME GROUND is at the same potential as Logic Gnd (pin 1 6). 


18 


FUSED 5 V - 1 A maximum. 


19-30 


SIGNAL GROUNDS are the Logic Grounds and Returns for all input 
and output signals. 


31-35 


NOT USED - These leads should be left unconnected. 


36 


NSelectln (not connected). 



50 



Zebra S- Series User's Guide 



Preventive Maintenance 



Overview 



This section contains preventive maintenance information for the Zebra 
S-Series Printer. These procedures may be performed by the operator. 



Cleaning 



Exterior Surfaces 



Interior 



The exterior surfaces of the printer may be cleaned as required by using a 
lint-free cloth. Do not use harsh or abrasive cleaning agents or solvents. If 
necessary, a mild detergent solution or desktop cleaner may be used 
sparingly. 



Remove any accumulated dirt/lint from the interior of the printer using a 
soft bristle brush and/or vacuum cleaner. This area should be inspected 
after every four rolls of media. 



Cleaning Schedule 



AREA 


METHOD 


INTERVAL 


Printhead 


Isopropyl alcohol 


After every roll of media (or 500 
ft. of fanfold media) when 
printing direct thermal or after 
every roll of ribbon when printing 
in thermal transfer mode. 


Platen Roller 


Isopropyl alcohol 


Upper and Lower Media 
Sensors 


Air blow 


Media Path 


Isopropyl alcohol 


Ribbon Sensor 


Air blow 


Peel/Tear Bar 


Isopropyl alcohol 


As needed. 


Label Available Sensor 


Air blow 


Monthly. 


Cutter Module 


Isopropyl alcohol and/or air blow 


As needed. 



Table 4 



Zebra S- Series User's Guide 



51 



Printhead and Platen Roller 

Inconsistent print quality, such as voids in the bar code or graphics, may 
indicate a dirty printhead. For optimum performance, Zebra recommends 
performing the cleaning procedure on the following page after every roll 
of ribbon (perform this procedure after every roll of media for direct 
thermal printing). 

Note: Label Available Sensors are shown for location purposes only. 
They are not standard on all printers. 



Printhead 




Label 
Available 
Sensors 



Platen 
Roller 



Figure 21 



52 



Zebra S- Series User's Guide 



It is not necessary to turn printer power OFF prior to cleaning. If power is 
turned OFF, all label formats, images, and parameter settings stored in the 
printer's formatting RAM are lost. Permanent parameter settings stored in 
EEPROM are retained. When power is turned back ON, it may be 
necessary to reload some items. 

To clean the printhead and platen roller, open the media compartment 
door, refer to Figure 21, and perform the following steps: 

1 . Open the printhead by moving the printhead handle to the OPEN 
position. 

2. Remove the media and ribbon (if present). 

3. Moisten an applicator tip with Zebra Technologies Corporation- 
recommended solvent and wipe the print elements from end to end. 
(The print elements form the gray /black strip just behind the chrome 
strip.) Allow a few seconds for the solvent to evaporate. 

4. Rotate the platen roller and clean thoroughly with the solvent. 

5. Brush/vacuum any accumulated paper lint and dust away from the 
rollers and the media and ribbon sensors. 

6. Reload ribbon and/or media, close and latch the printhead, restore 
power (if necessary) and continue printing after the self test. 



Zebra S- Series User's Guide 53 



Extend the Life of Your Printhead 
With Save-A-Printhead Cleaning Film 

Challenge 

The printhead is the most critical component in your printer, and possibly the most 
delicate. It is a consumable item just like the brakes on your car, which eventually 
wears over time. However, with ongoing careful attention and maintenance, you can 
extend the life of the printhead! 

Below are photographs of three printheads. The first printhead is brand new. The 
second has printed over 1 million linear inches of thermal transfer labels and has been 
properly maintained. The third printhead has printed far fewer labels, but without 
proper care and maintenance, signs of abrasion and contamination build-up are 
evident. 



mi 





II 


Mill 






1 




New 



Over 1 Million Inches 
(Properly Maintained) 



Less Than I Million Inches 
(Without Proper Care) 



Preventive Maintenance 

For optimum performance, clean the printhead regularly after every roll of thermal 
transfer ribbon or after every roll of direct thermal labels. Take care when handling or 
cleaning the printhead by removing any jewelry that may scratch the printhead and 
use a grounding strap or anti-static mat to discharge static electricity that could 
damage the printhead. 

To start, only use the pre-soaked (isopropyl alcohol) cleaning swabs provided in the 
preventive maintenance kit. First, turn off the printer and open the printhead. Lightly 
blow or brush away any loose dust and lint particles within the print mechanism (i.e., 
rollers, media/ribbon sensors, and printhead). NEVER use any hard, metallic, or 
abrasive objects — such as a screwdriver — to remove adhesives or other 
contaminants that may have built up on the printhead. 

Next, press the swab tip against the printhead and swipe the print elements from end to 
end. Then, turn the platen rollers while wiping them from side to side. Repeat this 
step until the swab no longer shows dirt. 



54 



Zebra S- Series User's Guide 



Avoid the Contributing Factors to Premature Printhead Failure 

Abrasion - Over time, the movement of media/ribbon across the printhead wears 
through the protective ceramic coating, exposing and eventually damaging the print 
elements (dots). 

In order to avoid abrasion: 

• Clean your printhead frequently and use well-lubricated thermal transfer ribbons 
with backcoatings optimized to reduce friction. 

• Minimize printhead pressure and burn temperature settings by optimizing the 
balance between the two. 

• Ensure that the thermal transfer ribbon is as wide or wider than the label media to 
prevent exposing the elements to the more abrasive label material. 

Ribbon Backcoating and Buildup - Printhead contamination from direct thermal media 
or thermal transfer ribbon may occur in applications requiring high burn settings, high 
head pressure, high speed, or high volume. This contamination builds up on the 
printhead elements, creating a barrier to the heat transformation required to produce 
high quality images. Contaminant buildup occurs gradually and results in poor print 
quality that may look like faded print or failed print element(s). This build up is very 
resistant to cleaning with the pre-soaked swabs and is difficult to remove. 

In order to avoid ribbon backcoating and buildup: 

• Use thermal transfer ribbons that have been specially cured to provide backcoat 
protection for high demand applications. These ribbons — sometimes referred to 
as anti-stick ribbons — also dissipate static and provide more lubrication. 

• Follow the recommended Printhead Preventive Maintenance procedures. 

• Use our Save-a- Printhead cleaning film to remove printhead contamination 
buildup quickly and easily. 

Save-a-Printhead Cleaning Film 

What is Save-a-Printhead cleaning film ? A specially coated film that removes 
contamination buildup without damaging the printhead. 

What are the benefits of Save-a-Printhead cleaning film ? 

• Extends the life of your printhead. 

• Reduces maintenance downtime and the cost of replacing a printhead. 

• An inexpensive, easy and quick way to remove contaminants without having to 
remove the printhead. 

When should you use Save-a-Printhead cleaning film? When you see degrading print 
quality that looks like faded print or a failed print element(s) that cannot be corrected 
by cleaning with the pre-soaked cleaning swabs. 



Zebra S- Series User's Guide 55 



How to Use Save-a-Printhead Cleaning Film 

1 . Remove power from the printer. 

2. Open the printhead, remove media and ribbon from the print mechanism. 

3. Clean the printhead per the recommended Preventive Maintenance procedures. 

4. Position the Save-a-Printhead film in the print path, placing the glossy side down 
away from the printhead (matte side up). 

5. Close and latch the printhead. 

6. Slowly pull the full length of the film through the print mechanism. 

7. Again, clean the printhead per the recommended Preventive Maintenance 
procedures. 

8. Reload media and ribbon, close and latch the printhead. 

9. Print labels and inspect for improved print quality. If quality has not improved, 
contact our Technical Support staff. 

*Only one pass is required to remove contamination buildup. 

*Each strip of film can be used up to 10 times. 

^Discard the strip when residue buildup or other contamination is apparent. 

Note: In the case that a replacement printhead is needed, product from 
the Original Equipment Manufacturer (OEM) is strongly 
recommended to ensure that your printer and part warranties 
remain intact, and that the product performs optimally. 

How to Order Save-a-Printhead Cleaning Film Kits 

There are five kits to accommodate the different width printers. Each kit contains 
three 10" long strips of film. Reference the following table to order the kit for your 
printer: 

Order kit number: For Printers with Print Widths: 



46902 3.0"-4.0" 

44902 4.0"-5.0" 

48902 5.0"-6.0" 

38902 6.0"-7.0" 

22902 8.0"-9.0" 



56 Zebra S-Series User's Guide 



Media, Ribbon, and Label Available Sensors 

These sensors should be cleaned on a regular basis to ensure proper 
operation of the printer. To locate the position of these sensors, refer to 
Figure 21 on page 52, Figure 24 on page 61, and Figure 25 on page 62. 

Cutter Module 

Periodically, the cutter module should be cleaned to remove paper dust and 
label residue. Cleaning the cutter module ensures that labels are cut 
properly and not jam in the cutter mechanism. Refer to Figure 22. 

When the stationary cutter blade becomes gummed up with label adhesive 
or paper debris, clean it with a cotton swab moistened with isopropyl 
alcohol. If the cutter performs unsatisfactorily after it has been cleaned, 
refer to Volume 1 of the Maintenance Manual. 




Figure 22 



Zebra S- Series User's Guide 



57 



Lubrication 



CAUTION: Some commercially available lubricants will damage 
the printer if used. 

Lubrication of the S-Series Printer should be performed by a qualified 
service technician according to the directions provided in Volume 1 of the 
Maintenance Manual. 



58 Zebra S- Series User's Guide 



Adjustments 



Toggle Positioning 

Note: The \05Se printer has one toggle; the 1605 printer has two 
toggles. 

The toggle(s) should be positioned to provide even pressure on the media. 
Toggles are positioned by sliding them left or right to the desired location. 
On the l05Se, the single toggle should normally be positioned over the 
center of the media. If your printer has two toggles and you are using 
media too narrow to accommodate both toggles, position one toggle over 
the center of the media and decrease the pressure on the unused toggle. 

Printhead Pressure Adjustment 

If printing is too light on one side, or if thick media is used, you may need 
to adjust the printhead pressure. Refer to Figure 23 and follow the 
procedure below. 

1. Perform a PAUSE Key Self Test (see page 31). 

2. Lower the darkness setting until the printing is gray. 

3. Loosen the toggle position locking nut(s) located inside the "U" 
shaped bracket at the top of the toggle. 

4. Slide toggle(s) in the direction of the light printing. 

5. Using the knurled adjusting nuts on the shaft(s) of the toggle(s), 
increase or decrease spring pressure until the left and right edges of the 
printed area are equally dark. 

6. Increase darkness to optimum level for the media being used. 

7. Retighten the toggle position locking nut(s). 

Note: Printhead life can be maximized by using the lowest pressure that 
produces the desired print quality. 



Zebra S- Series User's Guide 59 



Adjusting 
Nut 




Label 
Available 
Sensors 



Figure 23 

Black Mark Media Sensor Position Adjustment 

This sensor position requires no adjustment or calibration by the user. 

Transmissive Media Sensor Position Adjustment 

The transmissive media sensor senses either the "web" between labels or a 
hole or notch in the media to determine the length of the label or ticket. 
The factory-set position should be sufficient for any width label using 
media with a web. However, if position adjustments are needed, follow 
these procedures beginning with the upper sensor. 



60 



Zebra S- Series User's Guide 



Upper Transmissive Media Sensor Position Adjustment 

To adjust the upper media sensor, refer to Figure 24 and follow these steps. 

1 . Remove the ribbon and locate the upper media sensor. 

2. Loosen the Phillips head screw. 

3. Slide the upper sensor along the slot to the desired position. When 
using media that has a web between labels, position the media sensor 
anywhere along the web (if you have labels with rounded corners, do 
not position the sensor where the rounded corners of the label might be 
detected). When using tag stock, position the upper sensor directly 
over the hole or notch. 

4. Tighten the Phillips head screw. 

Note: To adjust the upper section of the transmissive media sensor for 
the outside half of the media width, call a service technician. 



Upper Media 

Sensor 
Adjustment 




Figure 24 



Zebra S- Series User's Guide 



61 



Lower Transmissive Media Sensor Position Adjustment 

To adjust the lower media sensor, follow these steps: 

1 . Locate the lower media sensor assembly (a spring clip holding a small 
printed circuit board) under the rear idler roller. 

2. Position the sensor so that the two brass-colored infrared emitters are 
under the upper sensor by sliding it in its slot. 

3. Gently pull wires out of the printer frame as required. (Wires should 
have a little slack.) 

Note: If the sensor is being moved inward and a large loop of wire 
develops, remove the cover from the electronics side of the 
printer and gently pull the wires through. It is important that the 
wires be properly clamped so that they are not rubbed by any 
belts. 




Figure 25 



62 



Zebra S- Series User's Guide 



Media and Ribbon Sensor Sensitivity 
Adjustment 

Note: This adjustment is initially set by Zebra Technologies 

Corporation during final printer calibration. Under normal 
circumstances, further adjustments should not be necessary. The 
exception to this might be the use of media with extremely thick 
or thin backing, which could require re-adjustment of the sensor 
sensitivity. 

This adjustment may need to be performed if the paper/ribbon light comes 
ON with (1) the media and ribbon properly installed for thermal transfer 
mode or (2) media only properly installed for the direct thermal mode. 

The following procedure is used to perform the media and ribbon sensor 
and sensitivity range adjustment: 

1 . Turn the printer OFF. 

2. Open the printhead. 

3. Remove as many labels as needed to create at least 12" of blank 
backing material. Load the blank backing material under the 
printhead. 

Note: Be sure that blank backing material is positioned between the 
upper and lower media sensors. 

4. Remove the ribbon. (Sliding it as far from the printer wall as possible 
has the same effect as removing it.) 

5. Close the printhead. 

6. Hold down the PAUSE, FEED, and CANCEL keys while turning the 
printer ON. Once the printer is ON, release the keys. 

7. The following two sets of lights begin flickering, signifying that the 
adjustment has been made: 

• The PRINTHEAD and PAPER/RIBBON lights 

• The DARKEN and POSITION lights 

Note: If only one pair of lights is flickering, it indicates that the 

adjustment was not successful. Go back to step 1 and start over. 



Zebra S- Series User's Guide 63 



8. Open the printhead. 

9. Pull the media out of the printer until a label is positioned under the 
printhead. Move the ribbon back to its normal position. 

Note: Be sure that the label is positioned between the upper and lower 
media sensors. 

10. Close the printhead. 

1 1 . Press the MODE key to print a media and sensor profile and save the 
new values (see Figure 26). 

12. Perform the media calibration procedure on page 43. 



RIBBON 




100 




100 


080 

MEDIA- 
060 _ 

040 _ 

WEB- 
020 _ 


" 


080 
060 
040 


1 


020 






000 _ 


MEDIA MEDIA 


_000 



Figure 26 



64 



Zebra S- Series User's Guide 



Troubleshooting 



This section contains troubleshooting charts used to localize and repair the 
printer when faults occur. The procedures called out in the ACTION 
column may be performed by the operator or by a service technician when 
indicated. 



SYMPTOM 


DIAGNOSIS 


ACTION 


All indicator lights never light. 


No AC power applied to the 
printer. 


Ensure that the AC power 
cable is connected to a 
working voltage source. 


Faulty AC power fuse. 


Refer to page 9 for fuse 
replacement procedures. 


No voltage available from the 
internal power supply. 


Call a service technician. 


Printer locks up when running 
Power-On Self Test. 


An improper configuration was 
set. 


Reload factory defaults, then 
set correct parameters (see 
the instructions that begin on 
page 28). 


POWER light ON, other lights 
all OFF or all ON and the 
printer locks up. 


ROM CRC test has failed. 


Call a service technician. 


CALIBRATE light is OFF but 
all other lights are on. 


Dynamic RAM failed. 


Call a service technician. 


CALIBRATE light and 
POSITION light OFF but all 
other lights ON. 


FONT ROM error. 


Call a service technician. 


PRINTHEADIightisON, 
printing continues. 


Printhead under-temperature 
condition. 


Wait until printhead warms up. 
If condition persists and print 
quality is affected, move 
printer to warmer environment. 
If print quality is acceptable, 
no action is required. 



Zebra S- Series User's Guide 



65 



SYMPTOM 


DIAGNOSIS 


ACTION 


Printer stops. PAUSE light 
and PAPER/RIBBON light 
both ON. 


Media incorrectly loaded or not 
loaded. 


Load media correctly. See 
"Media Loading" on page 15. 


Misadjusted media sensor. 
Media not calibrated. 


Check position and sensitivity 
of media sensor and/or 
calibrate media. See "Media 
and Ribbon Sensor Sensitivity 
Adjustment" on page 63 and 
"Calibration" on page 43. 


Printer stops. PAUSE light ON 
and PAPER/RIBBON light 
FLASHING. 


Ribbon incorrectly loaded or 
not loaded. 


Load ribbon correctly. See 
page 11 for the 105Seand 
page 14 for the 160S. 


Malfunctioning ribbon sensor. 


Call a service technician. 


Printer stops. PAUSE light ON 
and PRINTHEAD light 
FLASHING. 


Printhead is not fully closed. 


Close printhead completely. 


Printhead open sensor not 
detecting its position flag. 


Call a service technician. 


Printer stops. PAUSE light 
and PRINTHEAD light both 
ON. 


Printhead element is 
overheated. 


Printer resumes printing when 
the printhead element cools. If 
condition persists, move 
printer to a cooler 
environment. 


Power supply is overheated. 


Printer resumes printing when 
the power supply cools. If 
condition persists, move 
printer to a cooler 
environment. 


Dots missing in printed area of 
label. 


Printhead element going bad. 


Call a service technician. 



66 



Zebra S- Series User's Guide 



SYMPTOM 


DIAGNOSIS 


ACTION 


Loss of printing registration on 
labels. 

(For Peel-Off Mode) 


Possible media sensor or 
calibration problem. 


Adjust media sensor position 
(see page 63) or calibrate 
media (see page 43). Call a 
service technician if 
necessary. 


Printer set for non-continuous 
media, but continuous media 
loaded. 


Set printer for correct media. 
See See "Media Loading" on 
page 15. 


Improperly adjusted media 
edge guides. 


Refer to "Media Loading" on 
page 15. 


Excessive vertical drift in top- 
of-form registration. 


Incorrect media loading. 


See "Media Loading" on 
page 15. 


Light vertical lines running 
through all labels. 


Dirty head or ribbon rollers. 


See "Printhead and Platen 
Roller" on page 52 for 
printhead cleaning 
instructions. 


Defective printhead elements. 


Call a service technician. 


Light printing or no printing on 
left or right side of the label. 


Printhead needs balancing. 


Adjust toggle pressure and/or 
position. See "Toggle 
Positioning" on page 59. 


Short printed lines at 45° to 
label edge on left or right side 
of label. 


Too much printhead pressure. 


Adjust toggle pressure and/or 
position. See "Toggle 
Positioning" on page 59. 


Fine gray lines on blank labels 
at angles. 


Wrinkled ribbon. 


See "Wrinkled ribbon." on 
page 68 under SYMPTOM. 


Truncated print, no print, or 
FEED button operates 
incorrectly while using non- 
continuous media. 


Media or ribbon improperly 
loaded. 


See "Media Loading" on 
page 15; "Ribbon Loading 
(1 05Se)" on page 1 1 ; and 
"Ribbon Loading (160S)" on 
page 14. 



Zebra S- Series User's Guide 



67 



SYMPTOM 


DIAGNOSIS 


ACTION 


Long tracks of missing print on 
several labels. 


Wrinkled ribbon. 


See "Wrinkled ribbon." on 
page 68 under SYMPTOM. 


Print element damaged. 


Call a service technician. 


In Peel-Off Mode, skewed or 
stuck labels. 


Glue material from back of 
labels causing media 
movement problems. 


Refer to "Cleaning" beginning 
on page 51 and perform 
maintenance and cleaning of 
the printer. 


Media and backing not 
properly aligned in printer. 


See "Media Loading" on 
page 1 5. 


Wrinkled ribbon. 


Ribbon fed through machine 
incorrectly. 


See "Ribbon Loading (105Se)" 
on page 11 and "Ribbon 
Loading (160S)" on page 14. 


Incorrect darkness setting. 


Set to the lowest value needed 
for good print quality. See 
"Adjusting the Print Darkness" 
on page 44. 


Incorrect printhead position or 
pressure. 


Adjust toggle pressure and/or 
position. See page 59. 


Media not feeding properly; it 
is walking from side to side. 


Make sure the media is snug 
by adjusting the media guide. 
See "Media Loading" on 
page 1 5. 


Continuing symptoms. 


Call a service technician. 


Continued wrinkled ribbon. 


Strip plate needs adjusting. 


Call a service technician. 


Misregistration and misprint of 
1 to 3 labels. 


Media was pulled when motor 
was not moving. 


Enter calibrate mode and 
recalibrate. See page 43. 


Incorrect media sensor 
position. 


See media sensor position 
adjustments on page 60. 


Media or ribbon improperly 
loaded. 


See "Media Loading" on 
page 15; "Ribbon Loading 
(105Se)" on page 11 ; and 
"Ribbon Loading (160S)" on 
page 1 4. 


Incorrect media sensor 
position or sensitivity. 


See "Media and Ribbon 
Sensor Sensitivity Adjustment" 
on page 63. 



Zebra S- Series User's Guide 



SYMPTOM 


DIAGNOSIS 


ACTION 


Changes in parameter settings 
did not take effect. 


Parameters are set or saved 
incorrectly. 


Reload the factory defaults. 
See "Calibration" on page 43 
and calibrate the printer. 
Then, cycle the power 
ON/OFF switch. 


If problem continues, there 
may be a problem on the main 
logic board. 


Call a service technician. 


ZPL II was sent to printer, but 
not recognized. The DATA 
light remains off. 


Communications parameters 
or DIP switches are set 
incorrectly. 


See "MODE Key Self Test" on 
page 33. Check for format or 
overrun errors. Reset 
communication parameters if 
needed. 


Prefix and delimiter characters 
set in printer configuration do 
not match the ones sent in the 
ZPL II label formats. 


Set the characters in the 
printer to match ZPL II format 
(see page 35). Check the 
configuration label for correct 
characters. If problem 
continues, check the ZPL II 
format for changed A CC, A CT, 
and A CD instructions. 


Printer does not operate in the 
mode specified in ZPL II or by 
calibration. 


Bank 2 DIP switches set to 
override ZPL II and calibration. 


Check Bank 2 DIP switch 
settings. See page 41. 


Printer does not feed media 
with black marks correctly. 


Printer not set up correctly. 


See page 43 to recalibrate the 
printer. Also, see page 41 to 
check Bank 2 DIP switch 
settings. 


Sensor is broken. (No red 
light is visible when looking 
through the front of the printer 
with the printhead open.) 


Call a service technician. 


In cutter mode, skewed or 
stuck labels. 


Cutter is dirty. 


Follow cutter module cleaning 
procedure on page 57. 


The cutter is not cutting labels 
cleanly. 


Cutter is dirty. 


Follow cutter module cleaning 
procedure on page 57. 


Cutter blades are dull. 


Replace the cutter module. 



Zebra S- Series User's Guide 



69 



SYMPTOM 


DIAGNOSIS 


ACTION 


Labels are jamming in cutter, 
or labels are being cut more 
than once. 


Cutter is dirty. 


Follow cutter module cleaning 
procedure on page 57. 


Label length is too short. 


Increase label length. 


For printers with the cutter 
option installed: printing 
stops. PAPER/RIBBON, 
PAUSE, and CANCEL LEDs 
on. 


Media jammed in cutter. 


Remove media, clean cutter 
module (see page 57). 


Connecting cable not 
connected to cutter module. 


Plug cable into cutter module. 


Cutter module is dirty. 


Clean cutter module (see 
page 57). 


End of the media is not 
positioned correctly on top of 
the platen. 


Reposition media so that the 
end is on top of the platen. 



70 



Zebra S- Series User's Guide 



Specifications 



Printer Specifications 

Printing Considerations 



Specification 


105Se 


160S 


Resolution (thermal transfer or 
direct thermal) 


203 dots per inch 
(8 dots per mm) 


Optional 152 dots per 
inch (6 dots per mm) 


Optional 300 dots per 
inch (12 dots per mm) 


203 dots per inch 
(8 dots per mm) 


Dot size 


0.00492" 
(0.125 mm) 


0.00656" 
(0.167 mm) 


0.0033" x 0.0039" 
(0.084x0.100 mm) 


0.00492" 
(0.125 mm) 


Maximum print width 


4.09" (104 mm) 


4.09" (104 mm) 


4.09" (104 mm) 


6.30" (160 mm) 


Maximum print 
length 


Standard 
memory 


15" 
(381 mm) 


26" 
(660 mm) 


18" 
(457 mm) 


9.5" 
(241 mm) 


With 512 KB 

additional 

memory 


39" 
(991 mm) 


39" 
(991 mm) 


N/A 


25" 
(635 mm) 


Bar code modulus ("X") 
dimension 


5 mil to 50 mil 


6.6 mil to 66 mil 


3.33 mil to 33.3 mil 


5 mil to 50 mil 


Thin film printhead with Energy Control 



Print Speeds 



Programmable constant printing speeds of 2" (51 mm), 3" (76 mm), 4" 
(102 mm), 5" (127 mm), and 6" (152 mm) per second. 

The \Q5Se with optional 300 dots/inch resolution supports programmable 
constant printing speeds of 2.4" (61 mm), 3" (76 mm), and 4" (102 mm) 
per second. 



Zebra S- Series User's Guide 



71 



Media Handling 

• Tear-Off Mode: Produced in strips. 

• Peel-Off Mode: Requires Peel-Off option or Media Rewind option. 
Labels are dispensed and peeled from the liner, and the liner is rewound 
internally. 

• Rewind Mode: Requires Media Rewind option. A full roll of printed 
labels is rewound internally. 

• Cutter Mode: Requires Cutter Module option. Media cut after 
printing; under software control. 

Media 



Media Specifications 


105Se 


160S 


Total media width 


Maximum 


4.5" 


114.3 mm 


7.2" 


182.9 mm 


Minimum 


0.75" 


19.05 mm 


2.0" 


50.8 mm 


Label length 


Maximum 


Refer to "Printing Considerations" on page 71 . 


Minimum 


Tear-Off 


0.63" 


16.00 mm 


0.63" 


16.00 mm 


Peel-Off 


0.50" 


12.8 mm 


0.50" 


12.8 mm 


Rewind 


0.50" 


12.8 mm 


0.50" 


12.8 mm 


Cutter 


1 .25" 


31.75 mm 


N/A 


N/A 


Total thickness 
(includes liner) 


Maximum (Printhead 
position may need to be 
adjusted above 0.01") 


0.015" 


0.381 mm 


0.015" 


0.381 mm 


Minimum 


0.0023" 


0.0584 mm 


0.0023" 


0.0584 mm 


Core size 


3.0" 


76.2 mm 


3.0" 


76.2 mm 


Maximum roll diameter 


8.0" 


203.2 mm 


8.0" 


203.2 mm 


Interlabel gap (0.11573 mm preferred) 


0.079" -0.157" 


2 mm - 4 mm 


0.079" -0.157" 


2 mm - 4 mm 


Maximum internal fanfold media pack size 
(LxWxH) 


8.0" x 7.2" x 
6.2" 


203.2 mm x 182.8 
mm x 157.4 mm 


8.0" x 7.2" x 
6.2" 


203.2 mm x 182.8 
mm x 157.4 mm 


Additional Specifications for Black Mark Media (optional on 105Se) 


Mark thickness (measuring 
parallel to label/tag edge) 


Minimum 


0.12" 


3 mm 


0.12" 


3 mm 


Maximum 


0.43" 


11 mm 


0.43" 


11 mm 


Mark width (measuring 
perpendicular to label/tag edge) 


Minimum 


0.43" 


11 mm 


0.43" 


11 mm 


Maximum 


Full media width. 


Full media width. 


Mark-to-mark registration tolerance 


+/-0.016" I +/-0.4 mm 


+/-0.016" I +/-0.4 mm 


Mark location 


Mark must be located on the inside of the media (closest to the printer's 
mainframe when loaded in the printer). 


Mark density 


>1 .0 ODU (Optical Density Unit) 


Density of the back of the media on which the 
black mark is printed 


0.5 ODU maximum 



72 



Zebra S- Series User's Guide 



Ribbon 



Ribbon Width 




105Se 


160S 


Zebra recommends using ribbon 
at least as wide as the media 
you are using to protect the 
printhead from wear. 


Maximum 


4.33" 


110 mm 


6.89" 


175 mm 


Minimum 


0.94" 


24 mm 


2.0" 


51 mm 


Standard 
lengths 


2:1 media to ribbon roll ratio 


984 ft. 


300 m 


984 ft. 


300 m 


3:1 media to ribbon roll ratio 


1476 ft. 


450 m 


1476 ft. 


450 m 


Roll size 


Inner diameter of core 


1.0" 


25.4 mm 


1.0" 


25.4 mm 


Outside diameter of full roll of ribbon 


3.2" 


81 mm 


3.2" 


81 mm 



<®l 



Zebra Programming Language II (ZPL II ) 



Downloadable graphics with data compression 

Bit image data transfer and printing, including mixing of 

text and graphics 

Format inversion 

Mirror image printing 

UPC/EAN (nominal 100% magnification [6 dots/mm and 
12 dots/mm only]) 

Bitmap and scalable fonts 

Programmable quantity with print pause 



Communicates in printable ASCII characters 

Controlled by a mainframe, minicomputer, PC, or other 
data entry device 

Serialized fields 

In-Spec OCR-A and OCR-B 

Four-position field rotation (0°, 90°, 180°, 270°) 



Bar Codes 



Code 11, Code 49, Code 93 

Code 39 (supports ratios of 2:1 , 3:1 , 5:2, 7:3) 

Interleaved 2 of 5 

CODABAR (supports ratios of 2:1 , 3:1 , 5:2) 

Industrial 2 of 5, Standard 2 of 5 

Plessey 

Code 128 (supports serialization in subsets B and C and 
UCC Case C Codes) 



UPC-A 

PDF 417 

POSTNET 

MSI 

E/EAN-8, E/EAN-13, EAN EXTENSIONS 

DataMatrix 

MAXICODE 



Zebra S- Series User's Guide 



73 



Standard Fonts 



The scalable smooth font (CG Triumvirate™ Bold Condensed) is 
expandable on a dot-by-dot basis, height- and width-independent, while 
maintaining smooth edges. Maximum size depends on available memory. 

Fonts A, B, C, D, E, F, G, and H are expandable up to 10 times, height- and 
width-independent; however, fonts E and H (OCR-A and OCR-B) are not 
considered in-spec when expanded. 

IBM Code Page 850 international character sets are standard in fonts A, B, 
C, D, E, F, G, and through software control. 

Note: See "Optional Printer Fonts" on page 81 for the availability of 
additional fonts. 



Font Matrices for 8 dots/mm Printhead (105Seand 160S) 


Font 


Matrix 
(in dots) 


Type 


Character Size 


Inches 


Millimeters 


Height 


Width 


Inter- 
character 
gap 


Height 


Width 


Char./lnch 


Height 


Width 


Char./ 
Inch 


A 


9 


5 


1 


U-L-D 


0.044 


0.029 


33.90 


1.13 


0.75 


1.33 


B 


11 


7 


2 


U 


0.054 


0.044 


22.60 


1.38 


1.13 


0.89 


C,D 


18 


10 


2 


U-L-D 


0.088 


0.059 


16.95 


2.25 


1.50 


0.67 


E 


28 


15 


5 


OCR-B 


0.138 


0.098 


10.17 


3.50 


2.50 


0.40 


F 


26 


13 


3 


U-L-D 


0.128 


0.079 


12.71 


3.25 


2.00 


0.50 


G 


60 


40 


8 


U-L-D 


0.295 


0.236 


4.24 


7.50 


6.00 


0.17 


H 


21 


13 


6 


OCR-A 


0.103 


0.093 


10.71 


2.63 


2.38 


0.42 


GS 


24 


24 





SYMBOL 


0.118 


0.118 


8.48 


3.00 


3.00 


0.33 





Default: 15 x 12 


U-L-D 


Scalable 


* U = Uppercase, L = Lowercase, D = Descenders 



74 



Zebra S- Series User's Guide 



Font Matrices for 6 dots/mm Printhead 


Font 


Matrix 
(in dots) 


Type 


Character Size 


Inches 


Millimeters 


Height 


Width 


Inter- 
character 
gap 


Height 


Width 


Char./lnch 


Height 


Width 


Char./ 
Inch 


A 


9 


5 


1 


U-L-D 


0.059 


0.039 


25.40 


1.50 


1.00 


1.00 


B 


11 


7 


2 


U 


0.072 


0.059 


16.93 


1.83 


1.50 


0.67 


C,D 


18 


10 


2 


U-L-D 


0.118 


0.079 


12.70 


3.00 


2.00 


0.50 


E 


21 


10 


3 


OCR-B 


0.138 


0.085 


11.72 


3.50 


2.17 


0.46 


F 


26 


13 


3 


U-L-D 


0.171 


0.105 


9.53 


4.33 


2.67 


0.38 


G 


60 


40 


8 


U-L-D 


0.394 


0.315 


3.18 


10.00 


8.00 


0.13 


H 


17 


11 


4 


OCR-A 


0.112 


0.098 


10.16 


2.83 


2.50 


0.40 


GS 


24 


24 





SYMBOL 


0.157 


0.157 


6.35 


4.00 


4.00 


0.25 





Default: 15 x 12 


U-L-D 


Scalable 


* U = Uppercase, L = Lowercase, D = Descenders 



Font Matrices for 12 dots/mm Printhead 


Font 


Matrix 
(in dots) 


Type 


Character Size 


Inches 


Millimeters 


Height 


Width 


Inter- 
character 
gap 


Height 


Width 


Char./lnch 


Height 


Width 


Char./ 
Inch 


A 


9 


5 


1 


U-L-D 


0.029 


0.016 


50.80 


0.73 


0.40 


2.00 


B 


11 


7 


2 


U 


0.036 


0.023 


33.86 


0.91 


0.58 


1.34 


C,D 


18 


10 


2 


U-L-D 


0.059 


0.033 


25.40 


1.49 


0.83 


1.00 


E 


42 


20 


6 


OCR-B 


0.138 


0.066 


23.44 


3.50 


1.67 


0.92 


F 


26 


13 


3 


U-L-D 


0.185 


0.042 


19.06 


2.15 


1.06 


0.76 


G 


60 


40 


8 


U-L-D 


0.198 


0.132 


6.36 


5.02 


3.35 


0.26 


H 


34 


22 


8 


OCR-A 


0.112 


0.072 


20.32 


2.84 


1.82 


0.80 


GS 


24 


24 





SYMBOL 


0.079 


0.079 


12.70 


2.00 


2.00 


0.50 





Default: 15x10 


U-L-D 


Scalable 


* U = Uppercase, L = Lowercase, D = Descenders 



Zebra S- Series User's Guide 



75 



Standard Printer Font Example 



FONT A -- ABCD 


xyz 12345 










FONT B — 


ABCDUXYZ 12345 










FONT D 


— ABCDwxyz 12345 










FONT 


E -- (OCR- 


•B) 


ABCD 


wxyz 


12345 


FONT F -- ABCDwxyz 


12345 






FONT G 







A 


z4 


FONT 


H -- (OCR-A) 


UPPER 


CASE 


ONLY 


FONT - 


- (Scalable) ABCDwxyz 12345 








FONT GS 


— ® © 











Physical 



Physical Characteristics 


105Se 


160S 


Height 


15.4" 


391 mm 


15.4" 


391 mm 


Width 


10.5" 


267 mm 


13.1" 


333 mm 


Length 


18.9" 


480 mm 


18.9" 


480 mm 


Weight (without options) 


43 lbs. 


19.5 kg 


55 lbs. 


24.9 kg 



Electrical 



• 115 VAC +15%/-20% or 230 VAC +15%/-15%; 48-62 Hz 

• 5 Amps @ 115V, 3 Amps @ 230V 

• UL 1950 Listed-Certified to CAN/CSA-C22.2 No. 950-M89; classified 
to IEC 950; complies with FCC and Canadian DOC class "A" rules 

• Carries the CE mark of compliance 



76 



Zebra S- Series User's Guide 



Communications Interface 



RS-232 at 110 to 19,200 baud (select from standard rates). Baud rate, 
data bits, parity, error detection protocol, and XON-XOFF or DTR/DSR 
handshaking are all switch-selectable. Stop bits are fixed at 1 . 

Compatibility Mode Parallel Interface. Maximum cable length: 10 ft. 
(304.8 cm). 



Environmental Ranges 



Operating temperature 


+41°FtO+104°F 


+5°Cto + 40°C 


Storage temperature 


-40°FtO+158°F 


^tO°C + 70 c C 


Non-condensing relative humidity 


Operating 


20% to 85% 


Storage 


20% to 85% 



Options and Accessories 

Peel-Off capability only* 

Cutter Module 

Cutter Catch Tray 

Media Rewind with rewind and peel-off capabilities* 

Fanfold Supply Bin 

ZebraNet™ 

Black Mark (Reflective) Sensor (1055e only) 

Scalable and bit-mapped smooth fonts 

Additional 512 KB memory (not available for \05Se [300 dots/inch]) 

* Peel-Off and Media Rewind options are mutually exclusive of the Cutter 
option. 



Zebra S- Series User's Guide 



77 




iaSk** 



78 



Zebra S- Series User's Guide 



Options 



Peel-Off 

Your printer may be equipped with the peel-off option. In the peel-off 
mode, only the label backing rewinds onto the rewind spindle. The 
peel/tear bar separates the label from the backing and the label available 
sensor activates the PAUSE mode to allow the operator to remove a 
printed label before subsequent labels print. 

This option cannot be added to a printer equipped with the optional Cutter. 

Cutter Module 

Your printer may be factory equipped with a cutter module that cuts labels 
after they have been printed. In addition, an optional cutter catch tray can 
be added to gather the labels once they have been cut. 

Media Rewind 

Your printer may be equipped with a media rewind option. This option 
supports both the rewind and peel-off modes of operation. 

In rewind mode, both labels and backing material rewind internally onto a 
user-supplied 3" core. A rewind bracket guides the media back to the 
rewind spindle after printing. 

This option cannot be added to a printer equipped with the optional Cutter. 

(See Peel-Off Option above for peel-off mode of operation.) 



Zebra S- Series User's Guide 79 



Fanfold Supply Bin 

Your printer may be equipped with an optional internal fanfold supply bin. 
It is used to load fanfold media within the media compartment, and it 
protects the media from environmental contaminants such as dust and dirt. 

The fanfold media supply bin is fully adjustable. It accommodates media 
from 1.57" (40 mm) to 3.54" (90 mm) wide (7.17" [183 mm] wide for the 
1605) and 3.5" (89 mm) to 8" (203mm) long. The maximum stack height 
for 8" long media is 4.5". Stack heights of 6.5" may be achieved with 
media less than 3.5" long. 

The fanfold supply bin may be installed in the field by the operator. To 
install the fanfold supply bin, follow the instructions included with the 
option. 

Note: The fanfold supply bin, peel-off option, and rewind option are 

mutually exclusive. The fanfold supply bin may not be installed 
in S-Series Printers with the peel-off option or the rewind option. 
Fanfold media may be used with the rewind spindle installed by 
using one of the external fanfold supply access slots (at the 
bottom and rear of the printer). 

External ZebralMet™ (Ethernet) Interface 

ZebraNet allows you to connect your printer to your ethernet network. 
This interface option is available for both 10Base-2 and lOBase-T 
networks. 

Black Mark (Reflective) Sensor 

Note: For the l05Se printer only. 

The reflective sensor utilizes continuous media with black marks printed 
on the back of the label liner. The black mark sensor determines the label 
length and the top of the label by detecting the black mark (similar to the 
way a transmissive sensor detects the gap or notch). 

This option is in addition to the standard transmissive sensor and is 
software- or switch-selectable. 



80 Zebra S- Series User's Guide 



Optional Printer Fonts 



The S-Series Printer can be optioned with character fonts in addition to 
those which are standard in the unit. 

Only one additional font can be installed in the printer at a time. This 
installation should be performed by a service technician. Once installed, 
this font can be used in addition to the standard fonts available in the 
printer. Refer to the ZPL II Programming Guide for further application 
information. 

Once an optional font is installed in the printer, the configuration printout 
from the CANCEL Key Self Test indicates the font type. 

The following optional Scalable Smooth Fonts are presently available 
(each is supplied as a complete set of standard, bold, italic, and bold italic 
styles): 



• CG Triumvirate™ 


• Futura™ 


• CG Times™ 


• Univers® 


• CGPalacio™ 





The following Bitmap Smooth Fonts (supplied in bold style only) are 
presently available: 



• CG Triumvirate™ Bold 


• CGTimes™Bold 


• CG Triumvirate™ Bold Condensed 


• CG Palacio™ Bold 


• Futura™ Bold, Univers® Bold 





Note: Type sizes of 6 pt, 8 pt, 10 pt, 12 pt, 14 pt, 18 pt, 24 pt, 30 pt, and 
36 pt are available. 

Examples of these optional fonts can be found on pages 89-90. 



Zebra S- Series User's Guide 



230 VAC Factory Setup 

Your Zebra S-Series Printer is factory set for 230 VAC operation if 
requested when the order is placed. If it is necessary to reconfigure your 
printer for operation at 115 VAC, see page 10. 

512 KB DRAM Memory Expansion 

Note: This option is not available for the l05Se 300 dots/inch printer. 

This option increases the printer's dynamic memory capacity from 0.5 MB 
to 1 MB. This supports longer label lengths and provides more capacity 
for downloadable fonts and large graphic image files. Extra memory may 
be installed at the factory or in the field. 

12-Dot/mm and 6-dot/mm Printhead 

Note: This option is available on the 105.Se printer only. 

Optional 300 dot-per-inch and 152 dot-per-inch printhead densities 
satisfy specified requirements for printing UPC/EAN symbologies or 
high-density graphics and small, crisp text. 



82 Zebra S- Series User's Guide 



Appendix 



230 VAC Power Cord 

Depending on how your Zebra S-Series printer was ordered, a power cord 
may or may not be included when the printer is optioned for 230 VAC, 
50/60 Hz operation. 

If a power cord is not supplied, you need to obtain one with the following 
specifications: 

• The overall length must be less than 3.8 meters. 

• It must be rated for at least 5 amps, 250 V. 

• The CHASSIS GROUND (EARTH) MUST BE CONNECTED to 

assure safety and reduce electromagnetic interference. This is done by 
the third wire in the power cord (see Figure 27). 







3 Conductor 
HAR 


CEE22 

Type 5 

Connector 


Contact 
View 




Attachment Plug 

Cap for Your 

Country 




nnnn — 


Neutral 

Earth 

Live 


■ 






1 




<<^ 





















Figure 27 

The plug cap should bear the certification mark of a known international 
safety organization (see Figure 28). 




Figure 28 



Zebra S- Series User's Guide 



83 



ASCII Code Chart 



HEX 


CHAR 




HEX 


CHAR 




HEX 


CHAR 




HEX 


CHAR 


00 


NUL 


20 


space 


40 


& 




60 


' 


01 


SOH 


21 


! 


41 


A 




61 


a 


02 


STX 


22 


" 


42 


B 




62 


b 


03 


ETX 


23 


# 


43 


C 




63 


c 


04 


EOT 


24 


$ 


44 


D 




64 


d 


05 


ENQ 


25 


% 


45 


E 




65 


e 


06 


ACK 


26 


& 


46 


F 




66 


f 


07 


BEL 


27 


' 


47 


G 




67 


g 


08 


BS 


28 


( 


48 


H 




68 


h 


09 


HT 


29 


) 


49 


I 




69 


i 


OA 


LF 


2A 


* 


4A 


J 




6A 


J 


OB 


VT 


2B 


+ 


4B 


K 




6B 


k 


OC 


FF 


2C 




4C 


L 




6C 


1 


OD 


CR 


2D 


- 


4D 


M 




6D 


m 


OE 


SO 


2E 




4E 


N 




6E 


n 


OF 


SI 


2F 


/ 


4F 


O 




6F 





10 


DLE 


30 





50 


P 




70 


P 


11 


DC1 


31 


1 


51 


Q 




71 


q 


12 


DC2 


32 


2 


52 


R 




72 


r 


13 


DC3 


33 


3 


53 


S 




73 


s 


14 


DC4 


34 


4 


54 


T 




74 


t 


15 


NAK 


35 


5 


55 


U 




75 


u 


16 


SYN 


36 


6 


56 


V 




76 


V 


17 


ETB 


37 


7 


57 


w 




77 


w 


18 


CAN 


38 


8 


58 


X 




78 


X 


19 


EM 


39 


9 


59 


Y 




79 


y 


1A 


SUB 


3A 




5A 


Z 




7A 


z 


IB 


ESC 


3B 


\ 


5B 


[ 




7B 


{ 


1C 


FS 


3C 


= 


5C 


\ 




7C 




ID 


GS 


3D 


= 


5D 


1 




7D 


} 


IE 


RS 


3E 


> 


5E 






7E 


~ 


IF 


US 


3F 


? 


5F 


- 




7F 


DEL 



Shaded values are NOT recommended for Command Prefix, Format Prefix, or 
Delimiter characters. 



84 



Zebra S- Series User's Guide 



Adjusting Darkness for "In-Spec" Bar Codes 

All direct thermal and thermal transfer materials do not use the same 
darkness setting. The best way to check for the proper darkness is to use a 
bar code verifier that actually measures bars/spaces and calculates the 
Print Contrast Signal (PCS) ratio. Without the assistance of a verifier, 
your eyes and/or the scanner to be used in the system may be used for 
picking the optimum darkness setting. What follows is a simple yet 
effective method for adjusting the darkness to print "in-spec" bar codes. 

1 . Load media according to the appropriate media loading and ribbon 
loading instructions beginning on page 1 1 . Ensure that the proper 
print method has been selected. 

2. With power OFF, press and hold the FEED key. 

3. Turn the printer power ON, then release the FEED key. The printer 
begins printing test labels. 

4. Print a label, then press the PAUSE key. The label contains several bar 
codes as well as other printer information. Normal bar codes are 
printed in a horizontal format as they feed out of the printer. Rotated 
bar codes are printed in a vertical format. 

5. Compare the test label printed to the bar codes in Figure 29 on 
page 87. If the test label appears too dark or too light, increase or 
decrease the darkness setting accordingly. 

6. Resume printing by pressing the PAUSE key again. Print a few labels 
at the new setting and verify that proper "in-spec" bar codes are being 
printed. Repeat steps 4, 5, and 6 until satisfied. 

7. To stop printing test labels, press the PAUSE key, then press the 
CANCEL key. 



Zebra S- Series User's Guide 85 



Label Darkness Levels 



Too Dark — Dark labels are fairly obvious. The normal bar code bars 
increase in size, and the openings in small alphanumeric characters may 
fill in with ink. It may be readable but not "in-spec". Rotated bar code 
bars and spaces run together. 

Slightly Dark — Slightly dark labels are not as obvious. The normal bar 
code is "in-spec". Small character alphanumerics are bold and could be 
slightly filled in. The rotated bar code spaces are small when compared to 
the "in-spec" code, possibly making the code unreadable. 

Slightly Light — Slightly light labels are, in some cases, preferred to 
slightly dark for "in-spec" bar codes. Both normal and rotated bar codes 
are "in-spec", but small alphanumeric characters may not be complete. 

Too Light — Light labels are obvious. Both normal and rotated bar codes 
have incomplete bars and spaces. Small alphanumeric characters are 
unreadable. 

In-Spec — The "in-spec" bar code can only be confirmed by a verifier, but 
it should exhibit some very visible characteristics. The normal bar code 
has complete, even bars and clear, distinct spaces. The rotated bar code 
also has complete bars and clear distinct spaces. Although it may not look 
as good as a slightly dark bar code, it is "in-spec". In both normal and 
rotated styles, small alphanumeric characters appear complete. 



Zebra S- Series User's Guide 



ROTATED BAR CODES 



31 




—» 




H 


» 

o 
o 

R 


SK 










9H 


Ss 




5 


B 


» 

n 
o 

n 


awn 


* 


= 


I 
w 

■a 
* 


si 


SB 


g| 




Sm^M 




SSE 




^^ 




SI El 


BB 









| TOO LIGHT 
SLIGHTLY LIGHT 


IN SPEC 




SLIGHTL 


YDARK 



I 



♦rnns:- z-3* 



HCODE-39* 



*C0DE-39» 



O 



CO 

> 

o 
o 

D 

m 



"CODE-39* 



TOO DARK 



Figure 29 



Zebra S- Series User's Guide 



87 



Optional Printer Fonts 

Your printer can be optioned with character fonts in addition to those that 
are standard in the unit. The following pages illustrate the optional fonts 
in each of the available styles. From time to time, additions may be made 
to the list of available fonts. Contact Zebra Technologies Corporation or 
your sales representative for further information. 

Only one additional font can be installed in the printer at a time. This 
installation should be performed by a service technician. Once installed, 
this font can be used in addition to the standard fonts available in the 
printer. Refer to the ZPL II Programming Guide for further application 
information. 

Once an optional font is installed in the printer, the configuration label 
printed during the CANCEL Key Self Test indicates the font type as the 
"Socket 2 ID". 



Optional Printer Fonts Currently Available 


Scalable Smooth Fonts (each is supplied as a 
complete set of Normal, Bold, Italic, and Bold 
Italic styles) 


Bitmap Smooth Fonts (supplied only in Bold). 
Type sizes: 6 pt, 8 pt, 10 pt, 12 pt, 14 pt, 18 pt, 
24 pt 


CG Triumvirate™ 


CG Triumvirate™ 


— 


CG Triumvirate™ Condensed 


CG Times™ 


CG Times™ 


CG Palacio™ 


CG Palacio™ 


Futura™ 


Futura™ 


Univers® 


Univers® 



* When equipped with the Bitmap CG Triumvirate™ Bold Condensed font, the 
105Se and 160S have the same font styles as the Stripe® S-300 printer. 



Zebra S- Series User's Guide 



Scalable Smooth Fonts (Optional) 



CG Triumvirate™ - Normal 0123456789.,?! AaBbCc 
CG Triumvirate™- Bold 0123456789.,?!AaBbCcDd 
CG Triumvirate™ - Italic 0123456789.,? lAaBbCcDdEe 
CG Triumvirate™ -Bold Italic 0123456789.,? !AaBb 
CG Times™ - Normal 0123456789,?! AaBbCcDdEeFfGg 
CG Times™ - Bold 0123456789.,?! AaBbCcDdEeFfGgHh 
CG Times™ - Italic 0123456789., ? lAaBbCcDdEeFfGgHUi 
CG Times™ - Bold Italic 0123456789.,? 'AaBbCcDdEeFf 
CG Palacio™ - Normal 0123456789,?! AaBbCcDdEeFf 
CGPalacio™- Bold 0123456789.,?!AaBbCcDdEeFiGg 
CG Palacio™ - Italic 0123456789.,? '.AaBbCcDdEeFfGg 
CGPalacio™ -Bold Italic 0123456789.,? .'AaBbCcDdEe 

CG Futura™ - Normal 0123456789,?! AaBbCcDd 

CGFutura™-Bold0123456789.,?!AaBbCcDdEe 

CG Futura™ - Italic 0123456789, ?! AaBbCcDdEeFf 

CG Futura™- Boldltalic 0123456789.,? 'AaBbCc 

Univers®- Normal 01234 56789.,?! AaBbCcDdEeFf 

Univers® - Bold 123456789.,? !AaBbCcDdEeFlGgHli 

Univers® - Italic 0123456789.,? '.AaBbCcDdEeFfGgHh 



Figure 30 
Bitmap Smooth Fonts (Optional) 



CG Triumvirate™ - Bold 0123456789.,?!AaBbCcDd 
CG Triumvirate™ Condensed - Bold 0123456789.,?!AaBb 
CG Futura™ - Bold 0123456789.,?!AaBbCcDdEe 

Univers® - Bold 0123456789.,?!AaBbCcDdEeFfGgHh 
CG Times™ - Bold 0123456789.,?!AaBbCcDdEeFfGgHh 
CG Palacio™ - Bold 0123456789.,?!AaBbCcDdEeFfGg 



Figure 31 



Zebra S- Series User's Guide 89 



Point Size Examples 



6pt 


©ABCDErGHIJKLMNO 


8pt 


@ABCDEFGHIJKLMNO 


10 pt 


©ABCDEFGHIJKLMNO 


12 pt 


©ABCDEFGHIJKLMNO 


14 pt 


©ABCDEFGHIJKLMNO 


18 pt 


©ABCDEFGHIJKLM 


24 pt ©ABCDEFGHIJ 

30 pt ©ABCDEFG 

36 pt @ABCDEF 



Figure 32 



90 Zebra S- Series User's Guide 



Glossary 



Alphanumeric — Indicating letters, numerals, and characters such as 
punctuation marks. 

Backfeed — The printer pulls the media and ribbon (if used) backward 
into the printer so that the beginning of the label to be printed is properly 
positioned behind the printhead. Backfeed occurs when you're operating 
the printer in tear-off or peel-off mode. 

Bar code — A code by which alphanumeric characters can be represented 
by a series of adjacent stripes of different widths. Many different code 
schemes exist, such as the universal product code (UPC) or Code 39. 

Black mark sensing — See "Reflective media sensor" on page 93. 

Calibration (of a printer) — A process in which the printer determines 
some basic information needed to print accurately with a particular media/ 
ribbon combination. To do this, the printer feeds some media and ribbon 
(if used) through the printer and senses whether to use the direct thermal or 
thermal transfer print method; whether continuous or non-continuous 
media is used; and, if non-continuous media, the length of individual 
labels/tags. 

Character set — The set of all letters, numerals, punctuation marks, and 
other characters that can be expressed by a particular barcode. 

Check digit — A character added to a barcode symbol that indicates to the 
scanner that it has read the symbol correctly. 

Continuous media — Label or tagstock that has no web (space between 
labels), notch, or gap to separate each label/tag; rather, the media is one 
long piece of material. 

Core diameter — The inside diameter of the cardboard core at the center 
of a roll of media/ribbon. 



Zebra S- Series User's Guide 91 



Diagnostics — Information about what printer functions are not working. 
This information is used for troubleshooting. 

Direct thermal printing — Printing in which direct thermal media is 
used. No ribbon is used; instead, the media is coated with a substance 
which reacts to heat to produce an image. 

Fanfold media — Media that comes folded in a rectangular stack rather 
than on a roll. 

Font — A complete set of alphanumeric characters in one style of type 
(e.g., Times, Helvetica). 

Ips "inches-per-second" — The speed at which the label or tag is printed. 
Zebra offers printers that can print from 2 ips to 12 ips. 

Label — An adhesive-backed piece of paper, plastic, or other material on 
which information is printed. 

Label available sensor — For printers equipped with the peel-off option, 
this sensor detects a printed label waiting to be taken or "picked" by the 
operator. While it detects this label, the printer does not print additional 
labels. Once the label has been taken, printing resumes. Also called 
"take-label sensor". 

Label backing (label liner) — The material on which labels are affixed 
during manufacture and is discarded or recycled by the end-users. Label 
backing (or liner) has a non-stick surface which allows the label to be 
easily removed by the end-user and placed in the desired location. 

Mark sensing — See "Reflective media sensor" on page 93. 

Media — Material onto which data is printed by the printer. Types of 
media include tagstock, continuous, fanfold, roll, etc. 

Media hanger — The hanger that supports media rolls and provides 
consistent media feed to the printhead. 

Non-volatile memory — Electronic memory that retains data even when 
power is removed. 



92 Zebra S- Series User's Guide 



Print speed — The speed at which printing occurs. For thermal transfer 
printers, this speed is expressed in terms of ips (inches per second). Zebra 
offers printers that can print from 2 ips to 12 ips. 

Printhead wear — The degradation of the surface of the printhead and/or 
the print elements over time. Heat and abrasion can cause printhead wear. 
Therefore, to maximize the life of your printhead, use the lowest print 
darkness setting (sometimes called "burn temperature" or "head 
temperature") and the lowest printhead/toggle pressure necessary. Also, 
use ribbon that is as wide or wider than the media to protect the printhead 
from the rougher media. 

Reflective media sensor — A sensor that detects a black mark on the back 
of media by measuring the reflectivity of the media. This mark helps the 
printer determine label size and print registration. 

Registration — Alignment of printing with respect to the top of a label/ 
tag. 

Ribbon — A band of inked material that is pressed by the printhead 
against the media to transfer an image onto the media, which in turn is 
pressed against the platen. A ribbon consists of a base film coated with 
wax or resin "ink." Zebra ribbons also have a back coating that protects 
the printhead from damage. The ribbon transfers ink onto the media when 
heated by the printhead. 

Ribbon wrinkle — A wrinkling of the ribbon caused by improper 
alignment of the strip plate and/or printhead pressure. This wrinkle can be 
seen just above the strip plate. Ribbon wrinkle can cause voids in the print 
and/or the spent ribbon to rewind unevenly. This is a condition that should 
be corrected by performing adjustment procedures. 

Roll media — Media that comes supplied rolled up on a core (usually 
cardboard). Contrast this with fanfold media, which comes folded in a 
rectangular stack. 

Supplies — Supplies is a general term for ribbon and media. 



Zebra S- Series User's Guide 93 



Tag — A type of media having no adhesive backing but featuring a hole or 
notch by which the tag can be hung. Usually tags are made of cardboard 
or other durable material. 

Take label sensor — See "Label available sensor" on page 92. 

Thermal direct printing — See "Direct thermal printing" on page 92. 

Thermal transfer printing — A printing method in which the printhead 
heats an ink- or resin-coated ribbon against the media, causing the ink/ 
resin to transfer onto the media. By selectively heating the ribbon, you can 
form an image on the media. See also "Ribbon" on page 93. 

Transmissive media sensor — A sensor that is located behind the 
printhead; detects the presence of media and, for non-continuous media, 
the position of the web, hole, or notch that separates each label. 

Void — A space where printing should have occurred but, due to some 
error condition, did not occur. A void can cause a bar code symbol to be 
read incorrectly or not be read at all. 



94 Zebra S- Series User's Guide 



Index 



Accessories, 77 
Adjustments 

Bar Code Darkness, 85 

Black Mark Media Sensor Position, 60 

Label Position, 44 

Media Rest Position, 44 

Media Sensitivity, 63 

Print Darkness, 44 

Printhead Pressure, 59 

Ribbon Sensor Sensitivity, 63 

Toggle Positioning, 59 

Transmissive Media Sensor Position, 60 
ASCII Code Chart, 84 

B 

Bar Codes 

Darkness Adjustment, 85 

Specifications, 73 
Black Mark Media Sensor Position, 60 
Black Mark Sensing Mode, 24 
Black Mark Sensor Option, 80 



Cabling Requirements, 47 
Calibration, 43 
CANCEL Key Self Test, 30 
CANCEL Key, 26 
Cleaning 

Cutter Module, 57 

Exterior Surfaces, 5 1 

Interior, 5 1 

Label Available Sensors, 57 

Printhead and Platen Roller, 52 

Schedule, 51 



Communications Interface, 77 

Configuration Mode 

Adjusting Label Position, 44 
Adjusting Media Rest Position, 44 
Adjusting Print Darkness, 44 
Calibration, 43 

Configuration, 39 

Cutter Mode, 18,25 

Cutter Module Option, 79 

D 

Damage, 7 
DCE Devices, 48 
DTE Devices, 48 



Fanf old Media, 18 

Fanfold Supply Bin Option, 80 

FEED Key and CANCEL Key Self Test, 34 

FEED Key and PAUSE Key Self Test, 33 

FEED Key Self Test, 32 

FEED Key, 26 

Font Specifications, 74-76 

Fonts, 81, 88-90 

Front Panel Keys 

CANCEL Key, 26 

FEED Key, 26 

PAUSE Key, 26 
Front Panel Lights, 27 
Fuse Replacement, 9 

I 

Inspection, 7 

L 

Label Position Adjustment, 44 
Lubrication, 58 



Zebra S-Series User's Guide 



95 



M 



Maintenance, 5 1 

Media Handling Specifications, 72 

Media Loading 

Cutter Mode, 18 

Fanf old Media, 18 

Peel-Off Mode, 17 

Rewind Mode, 17 

Roll Media, 15 

Tear-Off Mode, 17 
Media Requirements, 4 
Media Rest Position, 44 
Media Rewind Option, 79 
Media Sensing Modes 

Black Mark Sensing Mode, 24 

Transmissive Sensing Mode, 24 
Media Sensor Sensitivity, 63 
Media Specifications, 72 
Media Transport Modes 

Cutter Mode, 25 

Peel-Off Mode, 25 

Rewind Mode, 25 

Tear-Off Mode, 24 
MODE Key Self Test, 33 
MODE Key, 27 
Model Designation, 1 

o 

Option Switches 

Bank 1, 40 

Bank 2, 41 
Options 

230 VAC Factory Setup, 82 

512 KB DRAM Memory Expansion, 82 

Black Mark Sensor, 80 

Cutter Module, 79 

External ZebraNet Interface, 80 

Fanfold Supply Bin, 80 

Media Rewind, 79 

Peel-Off, 79 

Printer Fonts, 81 

Printhead, 82 



Parallel Cabling Requirements, 49 

Parallel Interface, 49 

PAUSE Key and CANCEL Key Self Test, 33 

PAUSE Key Self Test, 31 

PAUSE Key, 26 

Peel-Off Mode, 17,25 

Peel-Off Option, 79 

Power Connection 

115 VAC Operation, 10 

230 VAC Operation, 10 

AC Power Fuse Replacement, 9 

AC Voltage Selection, 8 
Power Cord, 83 
Power-On Self Test, 28 
Preventive Maintenance, 5 1 
Print Darkness, 44 
Printer Diagnostics, 34 
Printer Operating Modes 

Media Sensing, 23 

Media Transport, 24 
Printer Power Up, 21 
Printer Self Tests 

CANCEL Key, 30 

FEED Key and CANCEL Key, 34 

FEED Key and PAUSE Key, 33 

FEED Key, 32 

MODE Key, 33 

PAUSE Key and CANCEL Key, 33 

PAUSE Key, 31 
Printer Specifications 

Bar Codes, 73 

Communications Interface, 77 

Electrical, 76 

Environmental Ranges, 77 

Media Handling, 72 

Media, 72 

Options and Accessories, 77 

Physical, 76 

Print Speeds, 71 

Printing Considerations, 71 

Ribbon, 73 

Standard Fonts, 74-76 

ZPL II, 73 
Printhead DPI Option, 82 
Printhead Pressure Adjustment, 59 



96 



Zebra S-Series User's Guide 



R 



Removing Used Ribbon (105Se), 19 

Removing Used Ribbon (160S), 20 

Repacking, 5 

Reporting Damage, 7 

Reshipping, 8 

Rewind Mode, 17, 25 

Ribbon 

Loading (105Se), 11-13 

Loading (160S), 14 

Requirements, 4 

Sensor Sensitivity, 63 

Specifications, 73 
Roll Media, 15 
RS-232 Serial Data Port 

DCE Devices, 48 

DTE Devices, 48 

Hardware Control Signal Descriptions, 47 

Parallel Cabling Requirements, 49 

Parallel Interface, 49 

RS-232 Cabling Requirements, 47 

Signal Descriptions, 50 



Tear-OffMode, 17,24 

Toggle Positioning, 59 

Transmissive Media Sensor Position 

Lower Transmissive Media Sensor, 62 
Upper Transmissive Media Sensor, 61 

Transmissive Sensing Mode, 24 

Troubleshooting, 65 

u 

Unpacking, 7 



Voltage Selection, 8 

w 

Warnings 

230 VAC Operation, 4 

Installation, 4 

Repacking, 5 

Ribbon and Printhead Wear, 5 

Shielded Cable, 5 



Serial Number, 1 
Signal Descriptions, 50 
Site Requirements, 10 
Specifications, 71-77 
Storage, 8 

System Components, 45 
System Considerations 

Communications Code, 45 

Data Specifications, 46 

Interfaces, 46 
System Overview 

Communication Capabilities, 2 

Media Transport Mechanism Capabilities, 3 

Print Mechanism Capabilities, 2 

Thermal Transfer Printer Functions, 2 
System Requirements, 3 



ZebraNet Interface Option, 80 
ZPL II Label Formats, 35-37 
ZPL II Specifications, 73 



Zebra S-Series User's Guide 



97 




iaSk** 



98 



Zebra S-Series User's Guide 




Warranty Information 



All Zebra products are sold with warranties. Refer to the User's Guide for 
warranty information specific to each product. Here is some general 
information: 



Printer Products 



Printers . All printers (excluding printheads) are warranted against defect 
in material or workmanship for twelve (12) months from the purchase 
date. 

Proof of purchase or shipment date is required to validate the warranty 
period. The warranty becomes void if the equipment is modified, 
improperly installed or used, damaged by accident or neglect, or if any 
parts are improperly installed or replaced by the user. 

Printheads . Since printhead wear is part of normal operation, the original 
printhead is covered by a limited warranty as indicated below. Warranty 
period begins on purchase date. 

Printhead Warranty Period 

Barcode label printer printheads 6 months 

Card printer printheads 12 months 



Warranty Statement 



To qualify for this warranty, the printhead must be returned to the factory 
or to an authorized service center. Customers are not required to purchase 
Zebra supplies (media and/or ribbons) for warranty qualification. 
However, if it is determined that the use of other manufacturer supplies has 
caused any defect in the printhead for which a warranty claim is made, the 
user is responsible for Zebra's labor and material charges required to repair 
the defect. The warranty becomes void if the printhead is physically worn 
or damaged; also if it is determined that failure to follow the preventive 
maintenance schedule listed in the User's Guide has caused defect in the 
thermal printhead for which a warranty claim is made. 

Software . Software is warranted to be free of defects in material and 
workmanship for 30 days from the date of purchase. In the event of 
notification within the warranty period of defects, Zebra will replace the 
defective diskette or documentation. 

Batteries . Mobile printer batteries are warranted to be free of defects in 
material and workmanship for 90 days from date of purchase. In the event 
of notification within the warranty period, Zebra will replace the defective 
battery provided there has not been damage resulting from user abuse. 



Supplies Products 



Supplies are warranted to be free from defect in material and workmanship 
for a period of six (6) months for media and twelve (12) months for ribbon 
from the date of shipment by Zebra. This is provided the user has complied 
with storage guidelines, handling, and usage of the supplies in Zebra 
printers. 

Zebra's sole obligation under these warranties is to furnish parts and labor 
for the repair or possible replacement of products found to be defective in 
material or workmanship during the warranty period. Zebra may in its 
discretion issue a credit for any such defective products in such amount as 
it deems reasonable. 



Warranty Statement 



Warranty Exclusions & Conditions Statement 

The warranties provided above are the only warranties applicable. No 
other warranties, expressed or implied, are given. Zebra does not make any 
IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR 
A PARTICULAR PURPOSE in connection with its sale of products or 
services. While Zebra's desire is to be responsive to specific needs and 
questions, Zebra does not assume responsibility for any specific 
application to which any products are applied including, but not limited to, 
compatibility with other equipment. All statements, technical information 
or recommendations relating to Zebra products are based upon tests 
believed to be reliable yet do not constitute a guaranty or warranty. 

Zebra's maximum liability for warranty claims is limited to the invoice 
price of the product claimed defective. Zebra does not assume 
responsibility for delays or replacement or repair of products. Zebra shall 
not under any circumstances whatsoever be liable to any party for loss of 
profits, lost data, diminution of good will, or any other special or 
consequential damages whatsoever with respect to any claim made under 
agreement with Zebra. Specifically for software, Zebra is not liable for 
any incidental or consequential damages caused by abuse or 
misapplication of the software or by its use in violation of the U.S. 
copyright law or international treaty. 

No salesperson, representative, or agent of Zebra is authorized to make 
any guaranty, warranty, or representation that contradicts the foregoing. 
Any waiver, alteration, addition or modification to the foregoing 
warranties must be in writing and signed by an executive officer of Zebra 
to be valid. 



Warranty Statement 




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Warranty Statement